Industrial control motor overload protection

Industrial Power Control Systems : Motor Overload Protection Theewin Jidsathaporn IC/SSC Business 080-069-1222

First understand the workhorse of industry – The Motor ,[object Object],[object Object],[object Object],[object Object],[object Object]

Motor Failures : Why do motors fail?

Importance of Motor Protection ,[object Object]

Importance of Motor Protection ,[object Object],[object Object],[object Object],[object Object],What tripped? How did it trip? Was it preventable? Is anything else going to trip…when?

What Causes Motors to Fail? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Causes of Motors to Fail? ,[object Object],[object Object],[object Object],[object Object],[object Object],Under Locked Rotor conditions, the motor can draw between 6 to 10 times the normal full load current (FLC). Excessive heat will be generated by the windings !

Causes of Motors to Fail? ,[object Object],[object Object],[object Object]

Overcurrent Damage ,[object Object],[object Object],New Motor Winding Motor Winding Damaged by Excessive Heat

Functions of an Overload Relay ,[object Object],[object Object],[object Object],[object Object]

Typical Motor T/C Curve ,[object Object],[object Object],[object Object],[object Object],[object Object],100% 200% 300% 400% 500% 600% Typical T / C Curve “ I” Time in seconds % F u l l L o a d C u r r e n t

IEC Bimetallic Overload Relay ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],The Bulletin 193 bimetal overload relay offers all the features we expect from a thermal overload relay. Bulletin 193

Bimetal Operation ,[object Object],Balanced Overload Unbalanced Overload POWER CIRCUIT HEATER & BIMETAL STRIP DIFFERENTIAL MECHANISM BOTH TRIP BARS MOVE TO STARTER COIL CONTROL CIRCUIT POWER CIRCUIT DIFFERENTIAL MECHANISM MOVING TRIP BAR TO STARTER COIL CONTROL CIRCUIT

IEC Bimetallic Overload Relay Trip Indicator Stop Button Reset Button Mechanical Connection to contactor Electrical connections Current setting Scale for motor nameplate current Selector Automatic or Manual Reset Trip contact 95/96 and signal contact 97/98 Terminals for motor leads (below) Test operator Changes state on Trip and Signal contact Used for testing of control wiring installation

Bimetal Overload Relay - Product Family ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Electronic Motor Protection ,[object Object],[object Object],[object Object],[object Object],Performance Bul 825-P E3 and E3 Plus E1 Plus

E1 Plus Electronic Overload Relay Setting a new standard for electronic motor protection. The solid-state design provides accurate, reliable and repeatable protection. For simple to medium level applications. The patented modular design allows for easy expansion of capabilities through side mount accessory modules, that can cost effectively be added to help enhance your machine operation & protection.

E1 Plus Electronic Overload Relay ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

E1 Plus Electronic Overload Relay ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Over-molded power connections Latching mechanism

E1 Plus Electronic Overload Relay Latching Mechanism Insert Molded Power Stabs Reset Button Test Button DIP Switches (193-EE, 592-EE only) FLA Setting Dial Mechanical Trip Actuator Trip Status Indicator Control Terminals 95 & 96 / 97 & 98 Load Terminations

E3 and E3 Plus Electronic Overload Relay Offering a broad range of features in one complete, compact package to effectively manage and monitor motor performance in order to prevent and minimize production downtime. For medium to advanced protection requirements and demanding applications ,[object Object],[object Object],[object Object],[object Object],[object Object]

E3 and E3 Plus Electronic Overload Relay ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Enhanced Protection Thermal Overload ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Enhanced Protection Phase Loss ,[object Object],[object Object],[object Object],[object Object],[object Object],Phase loss is a leading cause of motor failure!

Enhanced Protection Ground Fault ,[object Object],[object Object],It is important to catch ground faults at the leakage stage!

Enhanced Protection Ground Fault ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Enhanced Protection Jam, Stall and Underload ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Enhanced Protection Temperature ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Enhanced Protection Current Imbalance ,[object Object],[object Object],[object Object],[object Object],[object Object]

Motor Diagnostics ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

E3 and E3 Plus Electronic Overload Relay

E3 Plus with Voltage Protection & Energy Monitoring ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],NEW

Voltage Protection ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Protection on the Line Side of the Contactor

Power Protection ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Energy Diagnostics ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Bulletin 825-P Motor Protection Relay ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Bulletin 825-P Motor Protection Relay ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

825P Application Machine #1 Machine #N P.F. = 0.95 Tx Contactor Branch Protection System Protection Motor Protection C MCCB MCCB MCCB MCCB MCCB

825-P (Metering, Statistical and History) Full Function Metering ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Soft Start : SMC-3 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Soft Start : SMC-3 Frame 1 Frame 2 Frame 3 Frame 4 Frame 5 37A 85A 135A 251A 480A 3.95 in 5.55 in 1.75 in 1…37 A 5.1 in 8.2 in 2.8 in 43…85 A

Soft Start : SMC-3 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Bypass contactor SCR – 3 phase control Line Connection FLA Setting = FLA of Motor Delta Connection FLA Setting = Motor FLA / 1.73

Soft Start : SMC-3 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Soft Start : SMC-3 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Soft Start : SMC-Flex ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],SMC-Flex

Soft Start : SMC-Flex ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Line Connection FLA Setting = FLA of Motor Delta Connection FLA Setting = Motor FLA / 1.73 Frame 1/2 Frame 3 Frame 4 Frame 5 Frame 6 Frame 7 85A 135A 251A 480A 780A 1250A

Soft Start : SMC-Flex ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Soft Start : SMC-Flex ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Protection Fault Diagnostics Fault Alarms Monitoring

Soft Start : SMC-Flex ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Consistency in Communications – SMC & Drives ControlNet DeviceNet Remote I/O Module Installation Installation Complete

THANK YOU Theewin Jidsathaporn IC/SSC Business 080-069-1222 www.ab.com www.rockwellautomation.com

Industrial control motor overload protection

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Industrial control motor overload protection