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Calculate Size of Contactor, Fuse, C.B, Over Load Relay of DOL Starter

This document provides information and calculations for sizing the components of a direct on line starter for a 5HP, 415V, 3-phase induction motor with a power factor of 0.8 and 750 RPM. It includes calculations for motor torque and current, followed by guidelines and formulas for sizing the fuse, circuit breaker, overload relay, and contactor based on the motor's full load current. The full load and starting currents are calculated, and it is determined that the motor requires a 6A fuse, 16A circuit breaker, 6A overload relay, and 6A contactor.

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2K views5 pages

Calculate Size of Contactor, Fuse, C.B, Over Load Relay of DOL Starter

This document provides information and calculations for sizing the components of a direct on line starter for a 5HP, 415V, 3-phase induction motor with a power factor of 0.8 and 750 RPM. It includes calculations for motor torque and current, followed by guidelines and formulas for sizing the fuse, circuit breaker, overload relay, and contactor based on the motor's full load current. The full load and starting currents are calculated, and it is determined that the motor requires a 6A fuse, 16A circuit breaker, 6A overload relay, and 6A contactor.

Uploaded by

erson1981
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Electrical Notes & Articles

Sharing Abstracts,Notes on various Electrical Engineering Topics.

Calculate Size of Contactor, Fuse, C.B, Over Load Relay of DOL Starter

Calculate Size of Contactor, Fuse, C.B, O/L of DOL Starter

 Calculate Size of each Part of DOL starter for The System Voltage 415V ,5HP Three Phase House
hold Application Induction Motor ,Code A, Motor efficiency 80%,Motor RPM 750 ,Power Factor 0.8 ,
Overload Relay of Starter is Put before Motor.
Basic Calculation of Motor Torque & Current:

 Motor Rated Torque (Full Load Torque) =5252xHP/RPM


 Motor Rated Torque (Full Load Torque)=5252×5/750=35 lb-ft.
 Motor Rated Torque (Full Load Torque) =9500xKW/RPM
 Motor Rated Torque (Full Load Torque)=9500x(5×0.746)/750 =47 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=3xMotor Full Load Current.
 Motor Starting Torque==3×47=142Nm.
 Motor Lock Rotor Current =1000xHPx figure from below Chart/1.732×415

Locked Rotor Current

Code Min Max

A 1 3.14

B 3.15 3.54

C 3.55 3.99

D 4 4.49

E 4.5 4.99

F 5 2.59

G 2.6 6.29

H 6.3 7.09
I 7.1 7.99

K 8 8.99

L 9 9.99

M 10 11.19

N 11.2 12.49

P 12.5 13.99

R 14 15.99

S 16 17.99

T 18 19.99

U 20 22.39

V 22.4
 As per above chart Minimum Locked Rotor Current =1000x5x1/1.732×415=7 Amp
 Maximum Locked Rotor Current =1000x5x3.14/1.732×415=22 Amp.
 Motor Full Load Current (Line) =KWx1000/1.732×415
 Motor Full Load Current (Line) = (5×0.746)x1000/1.732×415=6 Amp.
 Motor Full Load Current (Phase)=Motor Full Load Current (Line)/1.732
 Motor Full Load Current (Phase)==6/1.732=4Amp
 Motor Starting Current =6 to 7xFull Load Current.
 Motor Starting Current (Line)=7×6=45 Amp
(1) Size of Fuse:

Fuse as per NEC 430-52

Type of
Motor Time Delay Fuse Non-Time Delay Fuse

Single Phase 300% 175%

3 Phase 300% 175%

Synchronous 300% 175%

Wound
Rotor 150% 150%
Direct
Current 150% 150%

 Maximum Size of Time Delay Fuse =300% x Full Load Line Current.
 Maximum Size of Time Delay Fuse =300%x6= 19 Amp.
 Maximum Size of Non Time Delay Fuse =1.75% x Full Load Line Current.
 Maximum Size of Non Time Delay Fuse=1.75%6=11 Amp.
(2) Size of Circuit Breaker:

Circuit Breaker as per NEC 430-52

Type of
Motor Instantaneous Trip Inverse Time

Single Phase 800% 250%

3 Phase 800% 250%

Synchronous 800% 250%

Wound
Rotor 800% 150%

Direct
Current 200% 150%

 Maximum Size of Instantaneous Trip Circuit Breaker =800% x Full Load Line Current.
 Maximum Size of Instantaneous Trip Circuit Breaker =800%x6= 52 Amp.
 Maximum Size of Inverse Trip Circuit Breaker =250% x Full Load Line Current.
 Maximum Size of Inverse Trip Circuit Breaker =250%x6= 16 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%x4= 3 Amp
 Max Thermal Over Load Relay setting =120%xFull Load Current(Phase)
 Max Thermal Over Load Relay setting =120%x4= 4 Amp
 Thermal over Load Relay (Phase):
 Thermal over Load Relay setting =100%xFull Load Current (Line).
 Thermal over Load Relay setting =100%x6= 6 Amp
(4) Size and Type of Contactor:

Application Contactor Making Cap


Non-Inductive or
Slightly Inductive
,Resistive Load
AC1 1.5

Slip Ring Motor


AC2 4

Squirrel Cage Motor


AC3 10

Rapid Start / Stop


AC4 12

Switching of
Electrical Discharge
Lamp
AC5a 3

Switching of
Electrical
Incandescent Lamp
AC5b 1.5

Switching of
Transformer
AC6a 12

Switching of
Capacitor Bank
AC6b 12

Slightly Inductive
Load in Household
or same type load
AC7a 1.5

Motor Load in
Household
Application
AC7b 8

Hermetic
refrigerant
Compressor Motor
with Manual O/L
Reset
AC8a 6

Hermetic
refrigerant AC8b 6
Compressor Motor
with Auto O/L Reset

Control of Restive &


Solid State Load
with opto coupler
Isolation
AC12 6

Control of Restive
Load and Solid State
with T/C Isolation
AC13 10

Control of Small
Electro Magnetic
Load ( <72VA)
AC14 6

Control of Small
Electro Magnetic
Load ( >72VA)
AC15 10
 As per above Chart
 Type of Contactor= AC7b
 Size of Main Contactor = 100%X Full Load Current (Line).
 Size of Main Contactor =100%x6 = 6 Amp.
 Making/Breaking Capacity of Contactor= Value above Chart x Full Load Current (Line).
 Making/Breaking Capacity of Contactor=8×6= 52 Amp.

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