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Services &
Application
Guide
Application Guide
Motor Circuit Branch Circuit Protection
Motor Circuits – Choice of Overcurrent Protection
Motor circuits have unique characteristics and several
functions, such as short-circuit protection, overload protection
and automatic/ remote start/stop, that may be required.
Sometimes the comment is made that users prefer circuit
breakers because they can be reset. Let’s examine the choice
of either circuit breakers or current- limiting fuses for motor
branch circuit protection.
In the case to be examined, fuses and circuit breakers
(includes magnetic only circuit breakers which are called
MCPs or motor circuit protectors) are sized with the intent to
provide only short-circuit and ground fault protection for the
motor branch circuit protection per 430.52. Other means, such
as overload relays, provide the motor overload protection.
Typical thermal magnetic circuit breakers can only be sized for
motor branch circuit protection (typically 200% - 250% of
motor current) because if they are sized closer, the motor
starting current trips the circuit breaker’s instantaneous
mechanism. Magnetic only circuit breakers (MCPs) are
intentionally not provided with overload capability; they only
operate on short-circuit currents. There are some fuses such
as the FRS-R and LPS-RK fuses that can be sized close
enough for motor running overload protection or backup motor
running protection. But for the discussion in this section,
assume current-limiting fuses are sized only for motor
short-circuit and ground fault protection.
It is important to note that in this protection level being
discussed, a circuit breaker or fuses should only open if there
is a fault on the motor circuit. A separate overload protective
device, such as an overload relays, provides motor overload
protection per 430.32. Here are some important
considerations:
1. OSHA regulation 1910.334(b)(2) Use of Equipment states:
Reclosing circuits after protective device operation. After a circuit is
deenergized by a circuit protective device, the circuit may not be
manually reenergized until it has been determined that the equipment
and circuit can be safely energized. The repetitive manual reclosing of
circuit breakers or reenergizing circuits through replaced fuses is
prohibited. NOTE: When it can be determined from the design of the
circuit and the over-current devices involved that the automatic
operation of a device was caused by an overload rather than a fault
condition, no examination of the circuit or connected equipment is
needed before the circuit is reenergized.
So the speed of reclosing a circuit breaker after a fault is not an
advantage. The law requires that if the condition is a fault (that is the
only reason the circuit breaker or fuses should open on a motor circuit),
then the fault must be corrected prior to replacing fuses or resetting the
circuit breaker.
2. The typical level of short-circuit protection for the motor starter provided
by circuit breakers and MCPs is referred to as Type 1. This is because
most circuit breakers are not current-limiting. So, for a loadside fault,
the starter may sustain significant damage such as severe welding of
contacts and rupturing of the heater elements. Or the heater/overload
relay system may lose calibration. This is an acceptable level of
performance per UL 508, which is the product standard for motor
starters. Current-limiting fuses can be selected that can provide Type 2
“No Damage” short-circuit protection for motor starters.
Consequently, with circuit breaker protection, after a fault condition,
significant downtime and cost may be incurred in repairing or replacing
the starter. With properly selected fuses for Type 2 protection, after the
fault is repaired, only new fuses need to be inserted in the circuit; the
starter does not have to be repaired or replaced.
3. Circuit breakers must be periodically tested to verify they mechanical
operate and electrically tested to verify they still are properly calibrated
within specification. The circuit breaker manufacturers recommend this.
Typically circuit breakers should be mechanically operated at least every
year and electrically tested every 1 to 5 years, depending on the service
conditions. Modern current-limiting fuses do not have to be maintained
or electrically tested to verify they still will operate as intended. The
terminations of both circuit breakers and fusible devices need to be
periodically checked and maintained to prevent thermal damage. Plus
fuse clips should be periodically inspected and if necessary maintained.
4. After a circuit breaker interrupts a fault, it may not be suitable for further
service. UL 489, the product standard for molded case circuit breakers,
only requires a circuit breaker to interrupt two short-circuit currents at
its interrupting rating. Circuit breakers that are rated 100 amps or less
do not have to operate after only one short-circuit operation under “bus
bar” short-circuit conditions. If the fault current is high, circuit breaker
manufacturers recommend that a circuit breaker should receive a
thorough inspection with replacement, if necessary. How does one know
a circuit breaker’s service history or what level of fault current that a
circuit breaker interrupts? With modern current-limiting fuses, if the fuse
interrupts a fault, new factory calibrated fuses are installed in the circuit.
The original level of superior short-circuit protection can be there for the
life of the motor circuit.
5. After a fault, the electrician has to walk back to the storeroom to get new
fuses; that is if spare fuses are not stored adjacent to the equipment.
This does require some additional down time. However, if fuses opened
under fault conditions, there is a fault condition that must be remedied.
The electrician probably will be going back to the storeroom anyway for
parts to repair the fault. If properly selected current-limiting fuses are
used in the original circuit, the starter will not sustain any significant
damage or loss of overload calibration.
With circuit breaker protection on motor circuits, after a fault
condition, it may be necessary to repair or replace the starter,
so a trip to the storeroom may be necessary. And if the starter
is not significantly damaged, it may still need to be tested to
insure the let-through energy by the circuit breaker has not
caused the loss of starter overload calibration. Also, the circuit
breaker needs to be evaluated for suitability before placing it
back into service. Who is qualified for that evaluation? How
much time will that take?
In summary, resettability is not an important feature for motor
branch circuit (short-circuit) protection and resettability of the
branch circuit protective device is not a benefit for motor
circuits. As a matter of fact, resettability of the motor branch
circuit overcurrent protective device may encourage an unsafe
practice. The function of motor branch circuit protection is fault
protection: short-circuit and ground fault protection. Faults do
not occur on a regular basis. But when a fault does occur, it is
important to have the very best protection. The best motor
branch circuit protection can be judged by (1) reliability - its
ability to retain its calibration and speed of operation over its
lifetime, (2) current-limiting protection - its ability to provide
Type 2 “No Damage” protection to the motor starter, and (3)
safety - its ability to meet a facility’s safety needs. Modern
current-limiting fuses are superior to circuit breakers for motor
branch circuit protection.