AC Motor Protection 2012

ABB Oy, Distribution Automation AC Motor Protection
Vaasa, Finland
(3-phase induction and
synchronous motors)
Contents
1. AC motors, brief introduction

2. Introduction to motor protection
3. Thermal Protection, general
4. Thermal Overload Protection
5. Consecutive starts
6. Start-Up Supervision
7. Short-Circuit Protection
8. Unbalance Protection
9. Loss of Load
10. Earth Fault Protection
11. Miscellaneous
1. AC Motors
• Mechanical construction, stator and rotor

• Asynchronous and synchronous
Image from Machine Elements in Mechanical Design, Robert L. Mott

1. AC motor construction
There are only two main components: the stator and the rotor. The
stator contains a pattern of copper coils arranged in windings. As
alternating current is passed through the windings, a moving magnetic
field is formed near the stator.
Rotor
(rotating part)
Stator
(stationary part)
http://fi.wikipedia.org/wiki/Tiedosto:Asynchronmotor_animation.gif
1. Asynchronous (induction) motor
The rotor is constructed of a number of conducting bars running parallel
to the axis of the motor and two conducting rings on the ends. The
assembly resembles a squirrel cage, thus this type of motor is often
called a squirrel-cage motor.
Magnetic field formed by the stator induces a current in the rotor,

creating its own magnetic field. The interaction of these fields produces
a torque on the rotor. Note that there is no direct electrical connection
between the stator and the rotor.
http://fi.wikipedia.org/wiki/Tiedosto:Asynchronmotor
Image from Machine Elements in Mechanical Design, Robert L. Mott _animation.gif
1. Synchronous motor
The synchronous motor operates at exactly synchronous speed with no
slip. The rotor is of a constant polarity (either a permanent magnet or an
energized electromagnet) and the windings of the stator are wrapped in
such a way as to produce a rotating magnetic field. Such motors provide
very little torque at zero speed, and thus need some kind of separate
starting apparatus. Often a squirrel-cage rotor is built into the main rotor.
When the motor reaches a few percent of synchronous speed, the rotor
is energized and the squirrel cage becomes ineffective.
Image from Machine Elements in Mechanical Design, Robert L. Mott Animation © Motorola, Inc.
2. Introduction to motor protection
2.1 Need for protection

2.2 Protection relays
2.3 Some important definitions
2.1 Protection objectives
 Protection must be able to operate for abnormal conditions

 Internal faults
 Insulation failure (e.g. winding short-circuits, earth-faults)
 Bearing failure
 Under-magnetisation (synchronous motors)
 Externally imposed faults
 Overloading, insufficient cooling
 Start-up stress, reversed sequence starting
 Supply voltage unbalance or single phasing
 Over- and undervoltage
 Vibration
 Etc.
2.1 Causes for motor damages in industrial drives
Long time overheating 26 %
Insulation faults 30 %
Rotor or bearing faults 20 %
Faulty protection 5 %
Other causes 19 %
2.1 Protective functions needed
Faulty
protection 5 %
Other Thermal overload protection & RTD

causes 19 % Long time
Short-circuit and earth-fault
overheating
protection
26 %
Start-up supervision and thermal
Rotor or
sensor (RTD) unit
bearing
faults 20 % Insulation Continuous self-testing of the
faults 30 % protection relay
Other protective functions

2.2 Motor Protection Relays
 SPAM 150C
 REX521H07/H50
 REF541/3/5
 REM541/4/5
 REF542Plus
 REM610
 REM615, 611, 620
 REM630
2.3 Definitions
 Cold motor  motor temperature is same as

rated ambient temperature (40°C)
 Warm (hot) motor  motor has

rated operating temperature
2.3 Definitions
 Hot spots  at start-up and overload, some parts of the

motor heats up faster than others.
 End of stator windings
 Joints of the rotor rods and conducting rings
 temperature in this hot spots is higher than in the
stator iron, but after start-up/overload the temperature
will level out
Photo courtesy of Lincoln Motors, USA

2.3 How Stop/Start-up/Run conditions are defined
Stop = All phase currents are below 0.12 x IN.
Start-up = The phase currents rise from a value below

0.12 x IN to a value exceeding 1.5 x IN in less than
60 ms. The starting situation ends when the
currents fall below 1.25 x IN (more than 100 ms).
Run = The phase currents are over 0.12 x IN and the

start condition is not active.
Check the
< 60ms Overload exact values
1.50 xIn from the
relay manual
1.25 xIn
0.12 xIn
Stop Start-up Running Stop
3. Thermal protection, general
3.1 Motor thermal behaviour

3.2 Direct temp.meas. / current based model
3.1 Motor Thermal Behaviour
 Heat is developed at a constant

rate due to the current flow Electrical Mech.
energy Motor energy
 Light load => low current
 => small heat development Heat
 Rated => rated current Cooling air etc.
 => adequate heat development
 => temperature rises up to the motor operation temperature
 Overload => high current
 => high heat development
 => operation temperature will be exceeded
 => shortened life-time or damages
 Developed heat is proportional to the motor current (I2)

 Dissipation rate of the heat is proportional to the motor
temperature
 The higher the motor temperature is the faster heat is dissipated
 Motor temperature will increase or decrease until the
developed heat and the dissipated heat are in balance
+ -
Developed Dissipated
heat heat
 I2 R T
 Heating follows an exponential curve

 Rate of temperature rise depends on motor thermal time
constant t and is proportional to square of current
2
 I  
   1  e t 
t
  K  
 I FLC   
K = constant
Load
e = 2.7183 (Neper)
t = time
t t = time constant
I = highest phase current
 IFLC = Full Load Current
t
 Cooling also follows an exponential curve

 Rate of temperature drop depends on cooling time constant.
(Can be different when the motor is stopped.)
Load
t
 Heating with different loads

 High load
Low load
Time
 Heating with different time constants


Small t
Big t
Time
3.2 Direct temperature measurement
and
current based thermal model
2
 I  
   1  e t 
t
  K  
 I FLC   
 Sensor types
 RTD (resistance temperature detector)
 Pt 100, Pt250, Ni 100, Cu 10 etc
 Linear (or almost linear)
 Thermistors (NTC or PTC)

PTC
 Typically only PTC (positive temperature
coefficient) is supported
 PTC curve is of S-shape
 are like a switch which operates
at designed temperature
 cannot be used as thermometer
 Location
 Winding: embedded into the winding slot
 this is overheating protection
 Bearing
 Other: ambient temperature, cooling air
 Disadvantages
 Slow, does not detect rapid change (start-up, heavy overload)
 Advantages
 True information, i.e. detects also
 failures in the cooling system
 reduced cooling because of a dirt etc
2
 I  
   1  e t 
t
3.2 Current based thermal model   K  

 I FLC   
 Relay models the motor thermal behaviour

based on the phase currents
 this is overload protection
 Disadvantages
 Does not see cooling problems
 Advantages
 No direct temperature measurement needed
 Fast => more “accurate" in starts and heavy overloads
 Protection both for long time-constant (stator iron) and short
time-constant (winding ends, rotor bars) parts in the motor
4. Thermal overload protection (current based)
4.1 Time/current and thermal capability curves

4.2 Protection considerations
4.3 Different approaches for finding settings
4.4 SPAM 150C, REM610, 611, 615, 620 & 630
4.5 REM 54_, REF 54_, REX 521 (TOL3Dev)
4.6 REF 542Plus
4.7 Other settings
4.1 Time - current curves
 Motor start-up curves
10000
1000 Start-up, U=90%

Time in sec.
100
Start-up, U=100%
10
1
1 2 3 4 5 6 7
Stator current / rated current

4.1 Thermal limit curves
 Thermal capability, running
10000 Thermal capability for COLD motor

(motor started from (rated) ambient temperature)
1000 Thermal capability for WARM motor

Time in sec.
(long time motor temperature with rated load)

100
10
1
1 2 3 4 5 6 7

4.1 Thermal withstand curves
 Thermal capability, running & locked rotor
10000
1000
Time in sec.
100
COLD motor
10
WARM
motor
1
1 2 3 4 5 6 7

4.1 Example 1
Squirrel cage
motor HXR 500
• 900 kW
• 3 kV
• 200 A
• 1492 rpm
4.1 Example 2
4.2 Protection consideration
 Thermal overload protection should operate

 Before the motor thermal limits for running motor are exceeded
 Locked rotor curves can be handled with start-up supervision
 Note: relay thermal curve does not have to follow motor thermal
limit curves, it only must be below
 Relay should not operate
 At normal start-up conditions
 Example 1: relay cold curve goes below start-up curves

 Not good, motor can never be started (trips every time)
1000
Operation time (sec.)
100
10
1
1 2 3 4 5
 Example 2: relay warm curve is below start-up curves

 OK, but motor can be started only after some cooling time
1000
100
10
1
1 2 3 4 5
 Example 3: relay curves are between start-up and motor thermal

limit curves
 OK, but how much protection margin do you want?
10000
1000
100
10
1
1 2 3 4 5
4.3 Different approaches for finding settings
4.3 Motor thermal limit curves are known
 We have motor curves  relay thermal overload curves

must be below running motor thermal limit curves
(locked rotor curves can be taken care in start-up supervision)
10000
1000
100
10
1
1 2 3 4 5
4.3 Motor locked rotor time
 We know locked rotor time, but no curves

 Relay warm curve must be same or below given
locked rotor time
10000
1000
Locked rotor
time (warm)
100
10
1
1 2 3 4 5
4.3 Process oriented approach
 Find smallest possible setting which gives the required

number of starts without any problems.
 Must know: motor start-up time and current
 Must know: how many starts is allowed
 Settings allow you to “take out” from the motor all you need but
nothing more
 We simply assume that motor is big enough for this
4.4 Thermal overload protection in
REM610, REM611,
REM615, REM 620, REM630
& SPAM 150C
4.4 Thermal Overload Protection
 All these relays have basically same thermal overload

protection
 Single time-constant thermal model
 But motor has many parts, with own time-constants using only
one time-constant is not good enough especially with big motors
 Good protection needs two time-constant
 Short time-constant: winding, rotor
 Long time-constant: iron case
 These relays uses a weighting factor –setting (p)

 Commonly p = 50%
 Practically gives same result as if using 2 time-constants
 “Hot-spot” operation mode (p=50%)

 Motors designed for Direct-On-Line (DOL) starts
 At start-up or any overload situation the relay follows the
temperature of the “hot spots” (short time heating/cooling)
 After start-up or overload the temperatures inside the motor will
level out. Relay simulates this by “remembering only 50% of the
thermal rise during the start-up/overload”
% Thermal capacity
100
A A ΘA ≈ short time heating/cooling
ΘB ≈ long time heating/cooling
80
B
B
60 I > I I < I
Thermal level Thermal level

for eg. at start-up. at rated current.
 But first we must tell motor rated (FLC) current

I NM I N 2
 SPAM 150C I  
I N 1 I NR
 effects ONLY in thermal and undercurrent protection
I N 1 I NR
 REM610 PU scale  
I NM I N 2
 effects to ALL protection stages, except earth-fault
I NM I N 2
 REM615/MTPPR Rated current  
I N 1 I NR
 effect only in the function itself
 REM630/MTPPR Base value  setting (s)
IN1 = CT rated primary current IN2 = CT rated secondary current

INM = Motor rated current (FLC) INR = relay rated current
 Heating time constant -setting

 SPAM 150C, REM610: t6x (sec) = op.time for cold motor at 6 x rated current
 REM615, REM630: Time constant start, Time constant normal (sec)

 Time constant (t) = 32.15 x t6x
 Cooling time constant - setting

 SPAM 150C, REM610: Cooling factor Kc
 REM615, REM630: Time constant stop (sec)

 Time constant stop(t) = Kc x 32.15 x t6x
 New features in REM615, REM620, REM630 to give flexibility

 Separate time constants for normal run and starting
 Overload factor setting (SPAM/610 has fixed 1.05)
 Negative sequence factor (factory default = 0) if you want to emphasize effect of
unbalance to the thermal overload
 Initial thermal value (SPAM/610 has fixed 74%): Defines thermal level after power
up or clearing of thermal content
Cold Curve Warm Curve Motor rated

10000
1000
Operation time (sec)
100
10
1
0 100 200 300 400 500 600
Phase current (Amps)
REM 54_, REF 54_ & REX 521

(TOL3Dev function block)
 Motor rated (FLC) current

 Protective unit scaling
I N 1 I NR
scaling  
I NM I N 2
Where IN1 = CT rated primary current

IN2 = CT rated secondary current
INM = Motor rated current (FLC)
INR = relay rated current
Scaling must be done in all phases (channels) and

it effects to ALL functions using these channels
 Protective unit scaling

 Separete two time-constant thermal models for stator and rotor

 Thermal curves ready for 4 type of motors, 2 type of generators
and one transformer
Warm motor start-up after 15 min standstill, an example

100 %
90 %
Stator
80 %
Used thermal capacity [%]
70 %
Rotor
60 %
50 %
40 %
30 %
20 %
10 %
0%
0 500 1000 1500 2000 2500
Tim e [sec.]
 Basic settings = “motor data” etc.

 Advanced settings = “real settings”
 Advanced settings is automatically re-calculated by the relay
whenever Basic settings has been changed
In the CAP tool,

do not send the
advance settings to
the relay if the values
are nonsense
4.5 Motor rated current, exercise
 Motor rated current is 345A, CT = 500/5A,

we want short-circuit protection I>> = 3100A,
calculate
 protected unit scaling factor for REM 543
 I>> setting for REM 543
 I setting for SPAM 150C
 I>> setting for SPAM 150C

REF 542Plus
 Single time-constant thermal module,

but three time-constant settings
 Time Constant Off = motor is standstill
 Time Constant Normal = motor is running < 2×IMn
 Time Constant Overheat = heavy overload or start-up
Warm Cold
10000
Time constant normal
1000 Time constant overload

Operation time (sec)
Time
100 constant
Off
10
0 1 2 3 4 5 6
Current (xIMn)
4.7 Other settings in thermal protection
4.7 Other settings: Cooling time-constant
 Cooling when motor is at standstill IC411

 Methods of cooling (IC-code)
standard IEC 34-6
 Self-circulated cooling (IC_11) IC71W

 stop the motor and cooling is 4..6 times
slower because fan is stopped also
 Heat exchangers
cooling is 1..2 times slower
IC86W
 Setting names: cooling factor Kc,

time constant stop/off
4.7 Other settings: Prior alarm level
 Setting considerations
 Should be higher than the thermal level of the motor
which has been running for a long time with full load
 Should give enough time to reduce the load
 Generally, prior alarm level is set to 80 .. 95 % of the trip level
 Undesirable alarms?
 At motor restart (compare alarm level to restart-inhibit margin)
 At relay power-on
 Relay has no memory of the situation before power-off, therefore a
hot (warm) motor condition is assumed. For example SPAM 150C
begins from 74% after power-on.
4.7 Other settings: restart inhibit
 How to prevent motor start when the temperature is

WAIT
too high?
 Exampe: motor temperature is high, but below relay trip
level. If we start motor, the temperature will rise too high
and relay trips.
 Answer: set and use the “restart inhibit” correctly
 Relay prevents starting untill the motor cools down
enough
 Typical error: restart inhibit is in series of OPEN circuit,

when it should be in series of the CLOSE button
 Setting (inh ):
 100% - “consumption of one start-up” - margin
100%
Margin
Consumption of
a single start-up
inh
time
 Consumption of a single start can can be calculated,

if the operation time for a cold motor with start-up
current is known
start  up time
consumptio n   100%
trip time
 Exercise 1, propose a suitable

setting for restart inhibition
 Thermal level before start-up was 15%
and immediately after 60%
 Exercise 2, propose a suitable

setting for restart inhibition
 Start-up time = 7.5 sec
 Trip time = 22 sec
5. Consecutive starts
Cumulative start-up counter
 General
 Supplementary & Backup protection to the thermal overload
 Limits the number of consecutive starts  protection against
cumulative thermal stress caused by the starts
 Does not Trip but inhibits restarting!

 Number of consecutive starts?

 Typically 2 cold / 1hot (or 3 cold / 2 hot) starts within an hour
 Typically 10 min cooling time after previous start/running before
restarting.
 Check the motor manufacturer data, there can be surprises
 Sometimes the process / devices connected to the motor limits

the number of starts or set requirements for the minimum
standstill-time
 speed reduction gear
 etc
 Operation of a Cumulative Start-Up Counter

 The motor start-up time is added to the counter
 If the counter value exceeds the set inhibit-limit

the motor is not allowed to be restarted
 Inhibition is activated at the begin of the last
start-up. This does not abort starting!
 The counter value is decreased with a fixed

countdown rate
 Only after the counter value falls below inhibit-

limit the motor is allowed to be restarted
 Settings
 The inhibit level
tsi = (n-1)  ts +10%
where n = number of allowed start-ups
ts = starting time (in seconds)
 Countdown rate
Dts = ts / Dt
where ts = starting time (in seconds)
Dt = count time for one start-up (in hours)
 Compromising number of starts at nominal and under-voltage

 If calculated with nominal start-up time, fewer starts will be
allowed at under-voltage situation
 Exercise: calculate the settings

 Starting time = 60 sec.
 3 cold start-up is allowed in 4 hours
6. Start-up Supervision
= Locked Rotor (LR) protection

Start-up supervision with O/C protection
 Protection against prolonged start-up

 Definite time O/C protection  time setting must be long
enough to allow starting at undervoltage
I>
1000
Time in sec.
100
t>
10
1
1 2 3 4 5 10

Start-up supervision, thermal stress principle
 Thermal stress is proportional to I2t

 Represents energy needed to get the rotor to run full speed
 Represents thermal stress in case of stall
1000
Time in sec.
Max permitted
100 I2t locked rotor time
10
1
1 2 3 4 5 10

Safe stall time less than start-up time
 Typically Exe -type of motor

 Protection operation time set below the start-up time
 Protection must be blocked by a speed switch when the
rotor is speeding up
1000
Time in sec.
100
Max permitted
locked rotor time
10
1
1 2 3 4 5 10

Safe stall time less than start-up time
 Have both
 Stall = for locked rotor (LRT) protection
 I2t = for allowable running-up time (ART) protection (max. start-up time
allowed for the motor in case the rotor starts to rotate, but because of external problem or too
high mechanical load the start-up is prolonged)
1000
Stall
Time in sec.
I2t
100
Max permitted
locked rotor time
10
1
1 2 3 4 5 10

7. Shot-circuit protection
High-set Overcurrent Protection
 Interwinding short-circuit protection for the motor

 Phase-to-phase short-circuit protection for the feeder cable
 Typical setting 1.5 x start-up current
 Fast operation needed!
 Doubling effect
 I>> setting can be set for automatic doubling during a motor
start-up. Setting is selected 75% - 90% of start-up current
 High-set Overcurrent functions as a fast run-time stall protection
Phase current
I>> setting
time
Start-up Run-time STALL
 But when you have more than one OC stages

 Use one stage only for short-circuit, fast op.time
 Use another stage for run time stall (=jam protection)
 Blocked (or setting doubling) during start up
 Op.time can be longer, for example 2 sec
 REM615/630 has JAMPTOC function, which basically is OC
function with blocking during start up
8. Unbalance protection
Unbalance protection
 Unbalance causes negative sequence component of

phase current => causes a 2fN rotating flux to the rotor-
circuit => the rotor temperature starts to rise.
 Squirrel-cage induction motors can withstand unbalance
pretty good, but a full broken phase condition is not
allowed (about as severe situation as locked rotor)
 Two principles are used: NPS and Min-Max
 Inverse time characteristics gives selective operation
when multible motorfeaders.
Unbalance Protection
 3 phase currents are required

 In case of 2 x CT
 The sum of two phase currents
is connected to the relay
 NPS function block will work
nicely, but if possible set for
two-phase operation mode
 E/F current will cause errors
L1 L1
L1+L3
-(L1+L3)
L3 L3
Unbalance Protection
 Small voltage unbalance can cause high current

unbalance
I Start-up
DI  DU 
I FLC
 If, for example, the start-up current is 5 x FLC, a 2% voltage

unbalance causes 2% x 5 = 10% current unbalance
Positive Phase Sequence Reactance I Startup DI

 
Negative Phase SequenceReactance I FLC DU
Unbalance protection, NPS principle
 Negative Phase Sequence Current (NPS, I2) is

calculated from the phase currents vectors
 Inverse operation, a good estimation of the time constant K is
175
K
Istart  2
where Istart = start-up current of the motor x FLC
Unbalance protection, Min-Max Principle
 Phase discontinuity protection (SPAM 150C)

 The unbalance DI is calculated
IL max IL min
DI   100%
IL max
 If the phase currents are less than the FLC
IL max IL min
DI   100%
IFLC
 DI and negative phase sequence (NPS) are not the same!
 For example 12% NPS sensitivity requires a setting of 12%3 = 20.7%

9. Loss of Load
= Undercurrent protection
Undercurrent Protection
 Operates upon a sudden loss of load

 Can be used in applications where the loss of load
indicates a fault condition
 submersible pumps, when cooling is based on the constant flow
of liquid
 conveyor motors, broken belt
 Automatically blocked when the phase currents falls
below blocking level (8..12%)
10. Earth-fault Protection
Earth Fault Protection
 Protection typically non-

directional, definite time
 Core Balanced CT
(ring CT, toroidal CT) Cable
terminal box
 a must for sensitive protection
 recommended CT ratio 50/1
Isolation Cable Sheath
or higher
 CT construction
 Secondary side voltage
 Efficiency
Sheath
earthing
 When using sum connection of CTs

(known as Holmgren circuit) an
apparent EF-current will occur
 differencies of CTs
 saturation of CTs mainly at start-up
because of the DC-component
 Minimum recommended setting 10% of
the CT rated primary current
 Apparent E/F
current will occur
at startup due to
the saturation of
CT when sum
connection of CTs
is used.
 Avoiding problems of apparent E/F current

 Stabilising resistor
 Uo condition (directional protection)
 Long operation time, or
 Temporary blocking of operation at start-up
11. Miscellaneous
Contactor controlled drives
 Relay must have normally closed trip

contact
 Contactor cannot break high currents
 High-set O/C protection should be set out-of-
use
 E/F protection should be inhibited on high
overcurrents

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ABB Oy, Distribution Automation AC Motor Protection

1. AC motors, brief introduction

• Mechanical construction, stator and rotor

Image from Machine Elements in Mechanical Design, Robert L. Mott

Magnetic field formed by the stator induces a current in the rotor,

2.1 Need for protection

 Protection must be able to operate for abnormal conditions

Long time overheating 26 %

Rotor or bearing faults 20 %

Other Thermal overload protection & RTD

Other protective functions

 REM615, 611, 620

 Cold motor  motor temperature is same as

 Warm (hot) motor  motor has

 Hot spots  at start-up and overload, some parts of the

Photo courtesy of Lincoln Motors, USA

Start-up = The phase currents rise from a value below

Run = The phase currents are over 0.12 x IN and the

3.1 Motor thermal behaviour

 Heat is developed at a constant

 Developed heat is proportional to the motor current (I2)

 Heating follows an exponential curve

 Cooling also follows an exponential curve

 Heating with different loads

 Heating with different time constants

 Thermistors (NTC or PTC)

3.2 Current based thermal model   K  

 Relay models the motor thermal behaviour

4.1 Time/current and thermal capability curves

 Motor start-up curves

1000 Start-up, U=90%

Stator current / rated current

 Thermal capability, running

10000 Thermal capability for COLD motor

1000 Thermal capability for WARM motor

(long time motor temperature with rated load)

Stator current / rated current

 Thermal capability, running & locked rotor

Stator current / rated current

 Thermal overload protection should operate

 Example 1: relay cold curve goes below start-up curves

 Example 2: relay warm curve is below start-up curves

 Example 3: relay curves are between start-up and motor thermal

 We have motor curves  relay thermal overload curves

 We know locked rotor time, but no curves

 Find smallest possible setting which gives the required

 All these relays have basically same thermal overload

 These relays uses a weighting factor –setting (p)

 “Hot-spot” operation mode (p=50%)

Thermal level Thermal level

 But first we must tell motor rated (FLC) current

 REM630/MTPPR Base value  setting (s)

IN1 = CT rated primary current IN2 = CT rated secondary current

 Heating time constant -setting

 REM615, REM630: Time constant start, Time constant normal (sec)

 Cooling time constant - setting

 REM615, REM630: Time constant stop (sec)

 New features in REM615, REM620, REM630 to give flexibility

Cold Curve Warm Curve Motor rated

REM 54_, REF 54_ & REX 521

 Motor rated (FLC) current

Where IN1 = CT rated primary current

Scaling must be done in all phases (channels) and

 Protective unit scaling