CALCULATE SIZE OF CONTACTOR / FUSE / CB / OL RELAY OF

STAR-DELTA STARTER

BY
FAYSAL AHMED BHUIYAN
DHAKA , BANGLADESH
• Calculate Size of each Part of Star-Delta starter for 10HP, 415 Volt
Three Phase Induction Motor having Non Inductive Type Load, Code
A, Motor efficiency 80%, Motor RPM 600, Power Factor 0.8. Also
Calculate Size of Overload Relay if O/L Relay Put in
the wingdings (overload is placed after the Winding Split into main
and delta Contactor) or in the line (Putting the overload before the
motor same as in DOL).
BASIC CALCULATION OF MOTOR TORQUE & CURRENT:
• Motor Rated Torque (Full Load Torque) =5252xHPxRPM
• Motor Rated Torque (Full Load Torque)=5252x10x600=88 lb-ft.
• Motor Rated Torque (Full Load Torque) =9500xKWxRPM
• Motor Rated Torque (Full Load Torque)=9500x(10×0.746)x600 =119 Nm
• If Motor Capacity is less than 30 KW than Motor Starting Torque is 3xMotor Full
Load Current or 2X Motor Full Load Current.
• Motor Starting Torque=3x Motor Rated Torque (Full Load Torque).
• Motor Starting Torque==3×119=356 Nm.
• Motor Lock Rotor Current =1000xHPx figure from below Chart/1.732×415
• Overload protection (Heater or Thermal cut out protection) would be a device that
thermally protects a given motor from damage due to heat when loaded too heavy with
work.
• Allcontinuous duty motors rated more than 1HP must have some type of an approved
overload device.
• An overload shall be installed on each conductor that controls the running of the motor
rated more than one horsepower. NEC 430/37 plus the grounded leg of a three phase
grounded system must contain an overload also. This Grounded leg of a three phase
system is the only time you may install an overload or over – current device on a grounded
conductor that is supplying a motor.
• To Find the motor running overload protection size that is required, you must multiply the
F.L.C. (full load current) with the minimum or the maximum percentage ratings as follows;
• Maximum Size of Time Delay Fuse =300% x Full Load Line Current.
• Maximum Size of Time Delay Fuse =300%x13= 39 Amp.
• Maximum Size of Non Time Delay Fuse =1.75% x Full Load Line Current.
• Maximum Size of Non Time Delay Fuse=1.75%13=23 Amp.
• MAXIMUM SIZE OF INSTANTANEOUS TRIP CIRCUIT BREAKER =800% X FULL LOAD
LINE CURRENT.
• MAXIMUM SIZE OF INSTANTANEOUS TRIP CIRCUIT BREAKER =800%X13= 104 AMP.
• MAXIMUM SIZE OF INVERSE TRIP CIRCUIT BREAKER =250% X FULL LOAD LINE
CURRENT.
• MAXIMUM SIZE OF INVERSE TRIP CIRCUIT BREAKER =250%X13= 32 AMP.
(3) Thermal over Load Relay:

Thermal over Load Relay (Phase):

• Min Thermal Over Load Relay setting =70%xFull Load Current(Phase)

• Min Thermal Over Load Relay setting =70%x7= 5 Amp
• Max Thermal Over Load Relay setting =120%xFull Load Current(Phase)
• Max Thermal Over Load Relay setting =120%x7= 9 Amp
Thermal over Load Relay (Line):

• For a star-delta starter we have the possibility to place the overload protection in two positions,
in the line or in the windings.
• If O/L Relay Placed in Line: (Putting the O/L before the motor same as in DOL).Supply>Over Load
Relay>Main Contactor

• If Over Load Relay supply the entire motor circuit and are located ahead of where the power splits to the
Delta and Star contactors, so O/L Relay size must be based upon the entire motor Full Load Current.

• Thermal over Load Relay setting =100%xFull Load Current (Line).

• Thermal over Load Relay setting =100%x13= 13 Amp
• Disadvantage: O/L Relay will not give Protection while Motor runs in Delta (Relay
Setting is too High for Delta Winding)
• If O/L Relay Placed In the windings: (overload is placed after the Winding Split into
main and delta Contactor).Supply>Main Contactor-Delta Contactor>O/L Relay
• If overload is placed after the Point where the wiring Split into main and delta
Contactor, Size of over load relay at 58% (1/1.732) of the motor Full Load Current
because we use 6 leads going to the motor, and only 58% of the current goes
through the main set of conductors (connected to the main contactor).
• The overload then always measures the current inside the windings, and is thus
always correct. The setting must be x0.58 FLC (line current).
• Thermal over Load Relay setting =58%xFull Load Current (Line).
• Thermal over Load Relay setting =58%x13= 8 Amp.
• Disadvantage: We must use separate short-circuit and overload protections
(4) Size and Type of Contactor:
• Main and Delta Contactor:
• The Main and Delta contactors are smaller compared to single contactor used in a Direct on Line
starter because they Main and Delta contactors in star delta starter are controlling winding
currents only. The currents through the winding are 1/√3 (58%) of the current in the line.
These two contactors (Main contractor and Delta Contactor) are close during run. These rated at
58% of the current rating of the motor.
• Star Contactor:
• The third contactor is the star contactor and that only carries star current while the motor is
connected in star in starting. The current in star winding is 1/√3= (58%) of the current in delta,
so this contactor can be rated at 1/3 (33%) of the motor rating. Star contactor can be selected
smaller than the others, providing the star contactor pulls first before the main contractor. Then no
current flows when third contactor pulls.
• In star connection at start, the motor draws and delivers 1/3 of its full rated power.
• When the starter switches over to Delta, the motor draws full power, but since the contactors and
the overload relay are usually wired within the Delta, you need to use contactors and relay
which are only rated 1/√3 =58% of the full rated power of the motor.
• As per above Chart
• Type of Contactor= AC1
• Making/Breaking Capacity of Contactor= Value above Chart x Full Load Current (Line).
• Making/Breaking Capacity of Contactor=1.5×13= 19 Amp.
• Size of Star Contactor (Starting Condition) = 33%X Full Load Current (Line).
• Size of Star Contactor =33%x13 = 4 Amp.
• Size of Main Contactor (Starting-Transition-Running) = 58%X Full Load Current (Line).
• Size of Main Contactor =58%x13 = 8 Amp.
• Size of Delta Contactor (Running Condition) = 58%X Full Load Current (Line).
• Size of Delta Contactor =58%x13 = 8 Amp.
Summary:

• Type of Contactor= AC1

• Making/Breaking Capacity of Contactor=19 Amp.
• Size of Star Contactor =4 Amp.
• Size of Main Contactor = 8 Amp.
• Size of Delta Contactor =8 Amp.