BET 31 Lesson 2 - Disconnect and Protective Device

Lesson 2: Disconnect and Protective Devices |1
University of Makati
College of Technology Management
Electrical Technology
Learning Material
BET 31 : Industrial Motor Control

Lesson 2 : Disconnect and Protective Devices
BET 31: INDUSTRIAL AC MOTOR CONTROL

Lesson 2: Disconnect and Protective Devices
Objectives:
At the end of the lesson, you are expected to:
1. Describe disconnect and protective devices,
2. Understand the use and purpose disconnect and protective devices,
and
3. Determine the function of protective devices.
Introduction:
The lesson will present essential devices in motor control, these are
disconnects and protective devices, moreover, it includes fuses, circuit
breakers, GFCI’s and overload relay. This will be vital in the understanding
of motor control as you go through the lesson in industrial motor control.

Disconnects A disconnect is normally the first device in a motor
branch circuit. A single operating handle mounted on
the front of the enclosure makes and breaks power to
all lines supplying power to the motor controller when
repair or maintenance must be performed.
SYMBOL
DISCONNECT
Protective Various forms of protective devices are employed to

Devices
protect electrical circuits and equipment from injury
under abnormal conditions.

These devices may be classified as follows according to the type of
protection which they provide:
1. Overload protection 5. Reverse-current or power protection
2. Under load protection 6. Reverse phase rotation
3. Under voltage protection 7. Lightning and surge protection
4. Over voltage protection 8. Ground-fault protection
Relays and Releases
Protection for the various types of abnormal conditions is in many cases
provided by relays and release devices which actuate the opening of
circuit breakers or switches.
Method of Protection
1. Simple release device - the abnormal condition causes the functioning
of the release device, which acts directly upon a holding catch of the
switch or breaker mechanism.
2. Relay protection - the abnormal condition causes the functioning of a
relay, which opens or closes an auxiliary electric circuit, which in turn
trips the switch or breaker mechanism.

Types of Release Devices
1. Thermal release – this can be employed only for overload protection.
Their operation depends upon the deflection of a bimetallic element
as it is heated by the current of the circuit.
2. Magnetic release – consists of solenoid acting upon an iron plunger or
armature.
✓ For current protection, the coil of the solenoid is connected in series
with the circuit.
✓ For voltage protection, the coil is connected across the circuit
which is to be protected.
Types of Relay Devices
1. Thermal relay
2. Magnetic relay
3. Induction relay
Time Characteristics
1. Instantaneous or high-speed type – the circuit is opened
instantaneously upon the occurrence of the abnormal condition for
which the release or relay is set.

2. Definite time or time delay type – it is designed that there is a definite
time delay in its action. The abnormal condition must exist for a
definite time before the device will function to open the circuit. The
length of time of the disturbance required to cause the device to
function is independent of the magnitude of the disturbance.
3. Inverse-time type – it is designed that there is a time delay in its action.
The length of time of the disturbance required to cause the device to
function is dependent upon the magnitude of the disturbance. The
greater the magnitude of the disturbance, the quicker will the device
functions to open the circuit. All thermal relay and releases, owing to
the principle of their construction, provide inverse-time protection.
FUSES AND CIRCUIT BREAKERS
SYMBOL
FUSE (POWER OR CONTROL)

SYMBOL
Circuit
Circuit Circuit
Breaker w/
Circuit Breaker w/ Breaker w/
Thermal &
Interrupter Thermal Magnetic
Magnetic
O.L. O.L
O.L.
Fuses Fuses are current protection devices which contains
thin strips of metal which conduct the same current
that runs the motor. This fusible element melts when
current exceeds the acceptable levels.
Types of fuses
1. Plug fuses
2. Tamperproof fuse
3. Dual-element Plug fuse
4. Cartridge fuses

Standard (Non-Time Delay, Single Element) Fuses
Standard fuses protect against short circuits and ground faults using
thermal features to sense a heat buildup in the circuit. Once blown
standard fuses are no longer usable and must be replaced.
Time-Delay (Dual Element) Fuses
These are generally dual element fuses with both thermal and
instantaneous trip features that allow the motor starting current to flow for
a short time without blowing the fuse.

Circuit Breakers Circuit breakers, like fuses, are rated for specific voltage
and amperage ranges. Circuit breakers typically trip
faster than fuses under low-level faults common to
industrial motor control circuits. They are easily reset
following the correction of a fault.
Circuit breakers are sometimes used downstream of fuses in motor control
circuits. There, they protect the motor control system from low-level faults
while the upstream fuses provide protection against the less frequent but
more damaging high-level faults.
CUT AWAY VIEW OF A TYPICAL CIRCUIT BREAKER

L e s s o n 2 : D i s c o n n e c t a n d P r o t e c t i v e D e v i c e s | 10
Standard Ampere Ratings of Fuses and Fixed-Type Circuit Breakers (Art.
2.40.1.6 PEC 2000)
The standard ampere ratings for fuses and inverse-time circuit breakers
shall be 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 125, 150,
175, 200, 225, 250, 300, 350, 400, 450, 500, 600, 700, 800, 1000, 1200,
1600, 2000, 2500, 3000, 4000, 5000 and 6000 amperes.
Inverse Time Circuit Breaker
Inverse time circuit breakers have both thermal and instantaneous trip
features and are preset to trip at standardized levels. This is the most
common type of circuit breaker used in the building trades for
residential, commercial, and heavy construction.
✓ The thermal action of this circuit breaker responds to heat.
✓ If a motor’s ventilation inlets and outlets are not adequate to
dissipate heat from the windings of the motor, the heat will be
detected by the thermal action of the circuit breaker.
✓ If a short should occur, the magnetic action of the circuit breaker
will detect the instantaneous values of current and trip the circuit
breaker.

Instantaneous Trip Circuit Breaker
Instantaneous trip circuit breakers respond to immediate (almost
instantaneous) values of current from a short circuit, ground fault, or
locked rotor current.
✓ This type of circuit breaker will never trip from a slow heat buildup due
to motor windings overheating.
✓ A stuck bearing or a blanket of lint covering the inlets and outlets of
the motor’s enclosure will cause the motor to overheat and damage
the windings

Ground-Fault Ground fault circuit interrupters (GFCI) are an effective

Circuit
Interrupter means of preventing severe electrical shock. GFCIs are
installed to protect areas of the home, such as the
kitchen, bathroom or laundry, where electrical
appliances or products may come into contact with
water.
GFCIs are designed to protect against severe electrical shock or
electrocution from ground faults. Ground faults occur when the electrical
current in an appliance strays outside its normal path, and the human
body becomes part of the path through which the electrical current may
flow.
To protect against electrical shock, GFCI’s continuously monitor the
difference in current between the hot and neutral conductors. If the

electricity going to an outlet equals the current coming back from the
outlet, the GFCI is dormant. If the electricity going to an outlet is greater
than 5mA than the current coming back from the outlet, the GFCI will
open the circuit to stop of flow of electricity.


Overload Relay Motors larger than 1 horsepower must be provided
separate motor overload protection devices.
Overload relays protect a motor from excessive current
by monitoring current going into the motor. When
current is too high for too long, current to the coil of the
contactor is interrupted and the motor shuts down. It is
not capable of tripping when there is a short circuit.
SYMBOL
OVERLOAD RELAY
Magneti
Thermal
c
Overload Conditions
An overload occurs when too many devices are operated on a single
circuit or a piece of electrical equipment is made to work harder than it is
designed for.

For example, a motor rated for 10 amperes may draw 20, 30, or more
amperes in an overload condition.
In the following illustration a package has become jammed on a
conveyor causing the motor to work harder and draw more current.
Because the motor is drawing more current it heats up. Damage will
occur to the motor in a short time if the problem is not corrected or the
circuit is not shut down by the overload relay.
Temporary Overload Due To Starting Current
Electric motors are rated according to the amount of current they will
draw at full load. When most motors start, they draw current in excess of
the motor’s full-load current rating.

Motors are designed to tolerate this overload current for a short period of
time. Many motors require 6 times (600%) the full-load current rating to
start.
Some newer, high-efficiency motors may require higher starting currents
and as the motor accelerates to operating speed, the current drops off
quickly. The time it takes for a motor to accelerate to operating speed
depends on the operating characteristics of the motor and the driven
load. A motor, for example, might require 600% of full-load current and
take 8 seconds to reach operating speed.
Magnetic and Thermal Overloads
Overload devices are usually located in the motor’s starter and
connected in series with the motors electrical supply circuit and can be
operated by either magnetic or thermal action.
✓ The same amount of current passes through the overload relay and
the motor.
✓ If the current or heat through the overload device is higher than the
device’s rating, it trips and shuts down the electric power to the motor.

Magnetic Overload Relays
A magnetic overload relay is an electro-mechanical relay operated by
the current flow in a circuit.
1. When the level of current in the circuit reaches a preset value, the
increased magnetic field opens a set of contacts.
2. Electromagnetic overload relays operate on the magnetic action of
the load current flowing through a coil.
3. When the load current becomes too high, a plunger is pulled up into
the coil interrupting the circuit.
4. The tripping current is adjusted by altering the initial position of the
plunger with respect to the coil.

Thermal Overload Relays
A thermal overload relay is an electro-mechanical relay that is operated
by heat developed in the relay.
1. When the level of current in a circuit reaches a preset value, the
increased temperature opens a set of contacts.
2. The increased temperature opens the contacts through a bimetallic
strip or by melting an alloy that activates a mechanism that opens the
contacts.
3. Two types include melting alloy and the bi-metallic strip.
Melting-Alloy Thermal Overload Relays
These are probably the most popular type of overload protection.
1. The motor current passes through a small heater winding and under
overload conditions, the heat causes a special solder to melt allowing
a ratchet wheel to spin thus opening the control circuit contacts.
2. Must be reset by hand operation
3. Heater coil and solder pot in one unit non-tamper able

Bimetallic Thermal Overload Relays
This design uses a bimetal strip associated with a current-carrying heater
coil.
1. When an overload occurs, the heat causes the bimetal to deflect and
actuate a tripping mechanism which opens a set of contacts in the
control circuit interrupting power to the coil and opening the power
contacts.
2. Most relays are adjustable over a range from 85% to 115% of their
value.
3. They are available with ambient compensation. An ambient
compensated devices’ trip point is not affected by ambient
temperature and performs consistently at the same value of current.

A bimetal strip is made of two dissimilar metals bonded together. The two
metals have different thermal expansion characteristics, so the bimetal
bends at a given rate when heated. Under normal operating conditions
the heat generated by the heater element will be insufficient to cause the
bimetal strip to bend enough to trip the overload relay.
As current rises, heat also rises. The hotter the bimetal becomes, the more
it bends. In an overload condition the heat generated from the heater will
cause the bimetal strip to bend until the mechanism is tripped, stopping
the motor.

Overload Trip Time
The time it takes an overload to trip depends on the length of time the
overload current exists.
1. A Heater Trip Characteristics chart shows the relationship between the
time an overload takes to trip and the current flowing in the circuit
based on the standard 400C ambient temperature installation.
2. The larger the overload (horizontal axis), the shorter the time required
to trip the overload (vertical axis).
3. Any change from ambient temperature affects the tripping time of an
overload. For temperatures higher than 400C, the overloads trip at a
current rating less than the value of the overload.
Example: At 500C the overloads trip at 90% of their rated value. For
temperatures lower than 400C, the overloads trip at a current rating
greater than the rated value of the overload.

Number and Location of Over-load Units other than Fuses for Protection of
Motors
Number and Location of

Kind of
Supply System over-load units such as trip coils,
Motor
relays, or thermal cut-outs
2-wire, 1Ø, AC or DC,
1 in either conductor
ungrounded
1Ø, AC 2-wire, 1Ø, AC or DC,
1 in ungrounded conductor
or DC one conductor grounded
3-wire, 1Ø, AC or DC, 1 in either ungrounded
grounded neutral conductor
3Ø, AC 3, one in each ungrounded
Any 3Ø
or DC conductor

Selecting the Correct Overload device
Overload relays are designed to meet the special protective needs of
motor control circuits.
Overload Relays
✓ allow harmless temporary overloads, such as motor starting, without
disrupting the circuit
✓ will trip and open a circuit if current is high enough to cause motor
damage over a period of time
✓ can be reset once the overload is removed
Take the full-load current (FLA or IFL) and the service factor (SF) stamped
on the motor name plate.
1. SF of 1.0 (FLA X 115%)
2. SF of 1.15 (FLA X 125%)
Specification of Overload relay
1. Type
2. Current rating (maximum)
3. Maximum operating voltage
4. Number of heating element
5. Brand or trademark

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Lesson 2: Disconnect and Protective Devices |1

BET 31 : Industrial Motor Control

BET 31: INDUSTRIAL AC MOTOR CONTROL

Lesson 2: Disconnect and Protective Devices

At the end of the lesson, you are expected to:

1. Describe disconnect and protective devices,

2. Understand the use and purpose disconnect and protective devices,

3. Determine the function of protective devices.

disconnects and protective devices, moreover, it includes fuses, circuit

of motor control as you go through the lesson in industrial motor control.

BET 31: INDUSTRIAL AC MOTOR CONTROL

Disconnects A disconnect is normally the first device in a motor

branch circuit. A single operating handle mounted on

the front of the enclosure makes and breaks power to

all lines supplying power to the motor controller when

repair or maintenance must be performed.

Protective Various forms of protective devices are employed to

under abnormal conditions.

BET 31: INDUSTRIAL AC MOTOR CONTROL

These devices may be classified as follows according to the type of

protection which they provide:

1. Overload protection 5. Reverse-current or power protection

2. Under load protection 6. Reverse phase rotation

3. Under voltage protection 7. Lightning and surge protection

4. Over voltage protection 8. Ground-fault protection

Relays and Releases

Protection for the various types of abnormal conditions is in many cases

provided by relays and release devices which actuate the opening of

circuit breakers or switches.

1. Simple release device - the abnormal condition causes the functioning

switch or breaker mechanism.

2. Relay protection - the abnormal condition causes the functioning of a

relay, which opens or closes an auxiliary electric circuit, which in turn

trips the switch or breaker mechanism.

BET 31: INDUSTRIAL AC MOTOR CONTROL

Types of Release Devices

1. Thermal release – this can be employed only for overload protection.

Their operation depends upon the deflection of a bimetallic element

as it is heated by the current of the circuit.

2. Magnetic release – consists of solenoid acting upon an iron plunger or

✓ For current protection, the coil of the solenoid is connected in series

with the circuit.

✓ For voltage protection, the coil is connected across the circuit

Types of Relay Devices

1. Instantaneous or high-speed type – the circuit is opened

instantaneously upon the occurrence of the abnormal condition for

which the release or relay is set.

BET 31: INDUSTRIAL AC MOTOR CONTROL

2. Definite time or time delay type – it is designed that there is a definite

length of time of the disturbance required to cause the device to

function is independent of the magnitude of the disturbance.

3. Inverse-time type – it is designed that there is a time delay in its action.

The length of time of the disturbance required to cause the device to

function is dependent upon the magnitude of the disturbance. The

the principle of their construction, provide inverse-time protection.

FUSES AND CIRCUIT BREAKERS

BET 31: INDUSTRIAL AC MOTOR CONTROL

Fuses Fuses are current protection devices which contains

thin strips of metal which conduct the same current

that runs the motor. This fusible element melts when

current exceeds the acceptable levels.

BET 31: INDUSTRIAL AC MOTOR CONTROL

Standard (Non-Time Delay, Single Element) Fuses