“Coordinated” Motor Circuit Protection

A Guide to Understanding:
Short-Circuit Protection Devices,
Overload Protection Devices, and
Coordinated Protection
Table of Contents

Code Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Short-Circuit Protection Devices . . . . . . . . . . . . . . . . . . 3
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Type 2 Coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . 15
Eutectic alloy overload relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bimetallic alloy overload relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Solid-state overload relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Advanced Motor Protection . . . . . . . . . . . . . . . . . . . . . 20
Coordinated Motor Circuit Protection . . . . . . . . . . . . . . 22
Life of a Typical Motor Installation . . . . . . . . . . . . . . . . 26
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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 “COORDINATED” MOTOR CIRCUIT PROTECTION

CODE REQUIREMENTS
Whether you are designing motor circuits for use in North America,
Europe, or any other part of the world, several basic requirement are
typically specified for a motor circuit. In the U.S., the National Electrical
Code (NEC) is followed as the basis for most electrical installations. In
Canada, the Canadian Electrical Code (CEC) is followed, and in Europe,
each country has it’s own electrical code requirements that must be met. Due
to time and space limitations, we will address code issues in reference to the
NEC unless otherwise stated.
Article 430 of the NEC describes the requirements for installations
involving motors, motor circuits, and controllers. In Article 430, the
requirements for motor branch circuit short-circuit, and ground fault
protection and motor overload protection are specified. Figure 1 identifies
the control and protection components required for a motor branch circuit.

Figure 1
NEC Article 430 – Motor Branch Circuit Requirements

Supply

Disconnecting
Means

Short-Circuit Fuses
Protection Device or
(SCPD) Circuit Breaker

Motor Controller

Motor Overload Overload Relay

Protection

Motor

Now that we have identified the components required by code to

provide motor brand protection, let’s take a closer look at the available types
of short-circuit protection devices that will meet code requirements.
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“COORDINATED” MOTOR CIRCUIT PROTECTION

SHORT-CIRCUIT PROTECTION DEVICES

Short-circuit protection devices (SCPDs) can be classified into two
groups; fuses and circuit breakers. The NEC further recognizes four types of
fault protection devices and specifies their sizing limitations based on the
type of motor that is used in the circuit.
• Non-time Delay Fuse
• Dual Element (Time Delay) Fuse
• Instantaneous Trip (Magnetic-only) Circuit Breaker
• Inverse Time (Thermal-magnetic) Circuit Breaker
This review of short-circuit protection devices will not attempt to
endorse either circuit breakers or fuses since each type of device has its own
strengths and weaknesses. Instead, we will provide a clear understanding of
both types of SCPDs and let the application requirements determine which
protective device will best meet customer needs.

FUSES
Fuses are over-current protective devices that are placed in an
electrical circuit to protect the control components, wiring, insulation, and
motor from damage caused by excessive current and associated heat.
Overcurrents are considered any increase in continuous current above the
normal operating current level.
In motor circuits, overcurrents are classified in two different
categories. Motor overloads are any overcurrents up to or slightly above
locked rotor current (6-8 times FLA). This range of overcurrent is protected
by overload relay protection devices which will be discussed in more detail
later. Short-circuit overcurrents are those produced by short-circuit or ground
fault conditions with fault current levels in excess of 8 times FLA. In todays
industrial facilities, short-circuit overcurrents can easily reach 50,000A. If
the short-circuit overcurrents are not interrupted within fractions of a second,
severe damage to the electrical installation can occur including motor
damage, conductor and controller damage or even fires. In motor circuits,
fuses best provide protection from damage caused by short–circuit currents.
Throughout the world, many different types of fuses are used for
short-circuit protection in motor circuits. In North America, UL and CSA
fuses are most commonly used. In other parts of the world, DIN (German)
and BS88 (British) fuses are dominant. Even though the construction and
fastening means are quite different (See Figure 2), all these fuses still
perform the same essential function of short-circuit protection.

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 “COORDINATED” MOTOR CIRCUIT PROTECTION

Figure 2
The World of Fuses

BS88 Fuses
• IEC fuse type: Fuse-link for bolted connection
• Voltage rating: 660V AC
• Interrupting rating: 80,000A
• Standard cartridge sizes: A1, A2, A3, A4, B1, B2,
B3, and B4
• Typical ampere ratings: 2–400A
• Construction: Blade type for bolted connection
• Where commonly used: United Kingdom, Australia,
New Zealand, Asia, and Middle East

DIN Fuses
• IEC fuse type: Fuse-link with blade contacts
• Voltage rating: 660V AC
• Interrupting rating: 100,000A
• Standard cartridge sizes: 00, 0, 1, and 2
• Typical ampere ratings: 2–400A
• Construction: Blade type
• Where commonly used: Europe, South America,
Middle East, and India

UL/CSA Fuses
• Operation: Time-delay; Current-limiting
• UL fuse type: Class CC
• CSA fuse type: HRCI-MISC
• Voltage rating: 600V AC
• Interrupting rating: 200,000A
• Standard cartridge sizes: 30A
• Typical ampere ratings: 1–30A
• Construction: Ferrule type
• Where commonly used: North America

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“COORDINATED” MOTOR CIRCUIT PROTECTION

UL/CSA Fuses (cont.)

• Operation: Time-delay; Current-limiting
• UL fuse type: Class J
• CSA fuse type: HRCI-J
• Voltage rating: 600V AC
• Interrupting rating: 200,000A
• Standard cartridge sizes: 30A, 60A, 100A, 200A,
400A and 600A
• Typical ampere ratings: 1–600A
• Construction: 1–60A; Ferrule type 61–600A;
Blade type for bolted connection
• Where commonly used: North America

• Operation: Dual-element, Time-delay,

Current-limiting
• UL fuse type: Class RK1, RK5
• CSA fuse type: HCR-R
• Voltage rating: 250 and 600V AC
• Interrupting rating: 200,000A
• Standard cartridge sizes: 30A, 60A, 100A,
200A, 400A and 600A
• Typical ampere ratings: 1/10–600A
• Construction: 1–60A Ferrule Rejection type;
61–600A; Blade type for wedge clamp connection
• Where commonly used: North America

• Operation: Fast-acting; Current-limiting

• UL fuse type: Class T
• CSA fuse type: HCR-T
• Voltage rating: 300 and 600V AC
• Interrupting rating: 200,000A
• Standard cartridge sizes: 30A, 60A, 100A, 200A,
400A, 600A, 800A, 1200A
• Typical ampere ratings: 1–1200A
• Construction: 1–60A; Ferrule type; 61–1200A;
Blade type for bolted connection
• Where commonly used: North America

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 “COORDINATED” MOTOR CIRCUIT PROTECTION

CSA Fuses
• CSA fuse type: HRCII-C
• Voltage rating: 600V AC
• Interrupting rating: 200,000A
• Standard cartridge sizes: 30A, 60A, 100A,
200A, and 400A
• Typical ampere ratings: 1–400A
• Construction: Blade type for bolted connection
• Where commonly used: Canada
Fuses are designed to meet specific standard performance
requirements. In the case of UL and CSA fuses, specific characteristics such
as current ratings, voltage rating, fuse dimensions, rejection features,
withstand ratings, maximum I2T and Ip current let-through limits, trip time
parameters (time-delay) and more are specified in the standards.
Table A compares the performance requirements of various UL and
CSA fuse classes. As you can see, different class fuses with similar current
ratings can have significantly different results on I2T and Ip let-through
values.

Table A
Fuse Performance Requirements
UL Fuse Performance Requirements
per UL 198, 600 Volts, 100kA ➊
Ampere Max I2t  103 Max. Ip  103
UL Fuse Class
Rating (A) (A2-Sec.) (A)
K5, RK5 50 11
K1, RK1 10 10
30 J 7.0 7.5
T 7.0 7.5
CC 7.0 7.5
K5, RK5 200 21
K1, RK1 40 12
60
J 30 10
T 30 10
CSA Fuse Performance Requirements
per CSA C22.2 No. 106 ➊
Ampere Max I2t  103 Max. Ip  103
CSA Fuse Class
Rating (A) (A2-Sec.) (A)
HRCII-C 50 14
HRCI-R 50 14
30
HRCI-J 7 12
HRCI-T 7 12
HRCII-C 200 26
HRCI-R 200 26
60
HRCI-J 30 16
HRCI-T 30 16
➊ Fuses are tested on circuits with available fault currents between the threshold current of the fuse and 100,000
RMS symmetrical amperes.

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“COORDINATED” MOTOR CIRCUIT PROTECTION

FUSE MECHANICS
Figure 3 illustrates the typical operation of a dual element-time delay
fuse. As its name indicates, “dual element” means that the fuse incorporates
two separate current sensing elements arranged in a series configuration (A).
The overload element opens when continuous overcurrent conditions exist
(B). During an instantaneous short-circuit condition, the short-circuit
element will open in multiple locations (C), interrupting the short-circuit an
limiting the let-through I2T and Ip within the limits specified by the fuse
standard requirements.

Figure 3
Dual Element Time Delay Fuse
Short–circuit Element

Alloy Solder Connection

Overload Element
(A) Construction

(B) Opening on Overload Condition

(C) Opening on Short–circuit Condition

Several key benefits of using fuses for short-circuit protection

includes:
• Low initial cost
• Current limiting
• High interrupting ratings
• Newer small dimension fuses (Class J & CC)
• Reliable operation

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 “COORDINATED” MOTOR CIRCUIT PROTECTION

CIRCUIT BREAKERS
An increasingly popular method of providing short-circuit protection
in motor circuits is with the use of circuit breakers. Circuit breakers have
become very popular due to the fact that following a fault condition, circuit
breakers can be easily reset once proper troubleshooting and maintenance
procedures are completed. The ability to reset a circuit breaker following a
fault condition, allows the manufacturing process to begin operation with
minimal downtime.
There are many different types of circuit breakers on the market. In
discussing the world of circuit breakers, we will concentrate on two groups
of products. The first group will be UL/NEMA type molded case circuit
breakers which are very popular in North America, and IEC type circuit
breakers (motor circuit protectors) that are commonly used as short-circuit
protection devices outside North America.

North American Circuit Breakers

The most commonly used circuit breakers in North America are
referred to as “molded case circuit breakers” (MCCBs). These circuit
breakers meet UL 489, CSA C22.2 No.5 and NEMA AB-1 standards
requirements. These standards define circuit breaker characteristics such as
ratings, performance, corrosion protection, electrical spacings, testing
requirements, pass/fail criteria, insulating materials, current carrying parts,
terminal wire capacities, etc. There are many different types of molded case
circuit breakers including thermal-magnetic, magnetic-only, current-limiting,
fused circuit breakers, and many more. This discussion will concentrate on
thermal-magnetic and magnetic-only devices since they are the most popular
type used in industry today.

Thermal–magnetic Circuit Breakers

Thermal-magnetic (inverse time) circuit breakers provide both
thermal (overcurrent) and magnetic (short-circuit) protection within a single
device. For thermal overcurrent protection, thermal elements (bimetallic or
electronic) are used to protect the circuit components from damage caused by
continuous levels of high overcurrent. As current passes through the thermal
elements, they will deflect until a trip point is reached, at which time the
circuit breaker will trip, opening the motor circuit. The thermal action is also
associated with the characteristic of “inverse time” since low overcurrents
require longer trip times and high overcurrents result in shorter trip times.
For short-circuit protection, thermal-magnetic circuit breakers
incorporate a magnetic trip element. During a short-circuit condition, the
high fault current causes the magnetic trip element to release a latching
mechanism, tripping the circuit breaker and opening the motor circuit.

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 “COORDINATED” MOTOR CIRCUIT PROTECTION

International Circuit Breakers

Although North American type circuit breakers are used around the
world, motor circuit protectors that meet IEC 947 requirements are most
common outside North America. The IEC type circuit protector incorporates
several functions within a single device including On-Off push buttons for
local control and motor circuit isolation, adjustable bimetallic elements for
overload protection, and magnetic trip elements for short-circuit protection.
Since the IEC type circuit protectors do not meet the UL 489 molded case
circuit breaker requirements, they cannot be used as a stand-alone
short-circuit protection device as UL molded case circuit breakers or fuses in
the U.S. or Canada.

Figure 5
IEC Type Circuit Breakers

In the North American markets, the IEC motor circuit protectors

have achieved what is called “group motor rating.” This UL/CSA rating
allows several motor circuits, each using an IEC motor circuit protector, to
be protected with a single UL/CSA short-circuit protective device (Figure 6).

The elimination of individual motor circuit fuses or circuit breakers means

significant panel size reduction. NEC Article 430-53 outlines the
requirements for such installations.

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“COORDINATED” MOTOR CIRCUIT PROTECTION

Figure 6
North American “Group Motor Installation”

Disconnect
Switch Circuit
Breaker
OR
Fuses

Bulletin 140
Bul. Bul. Bul. Bul. Manual Starter
140 140 140 140 and Protector
Contactor
for Remote
Operation

M1 M2 M3 M4

In international markets, the IEC motor circuit protectors are

recognized and utilized as stand-alone short-circuit protection devices. Not
until the available fault current exceeds the interrupting capability of the the
motor circuit protector, do “back-up” short-circuit protection devices need to
be used (Figure 7).

Figure 7
Motor Installations Outside North America

Disconnect
Switch

Bulletin 140
Bul. Bul. Bul. Bul. Manual Starter
140 140 140 140 and Protector
Contactor
for Remote
Operation

M1 M2 M3 M4

Several key benefits of using IEC circuit breakers include:

• Provide useful “group motor ratings” for North American
applications
• Resetable after fault occurs
• Visible trip indication
• Overload protection
• Provide local On-Off and isolation
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 “COORDINATED” MOTOR CIRCUIT PROTECTION

TYPE 2 COORDINATION
Type 2 Coordination is a term used to describe a level of protection
that can be achieved by properly “coordinating” the selection of the
short-circuit protection device with the withstand capability of the motor
controller and overload protection device in the circuit. The concept of Type
2 Coordination originated from the IEC (International Electrotechnical
Commission) standard 947-4-1. In this standard, two levels of short-circuit
coordination are identified.
Type 1 Coordination is defined as follows:
“Under short-circuit conditions, the contactor or starter shall cause no
danger to persons or installation and may not be suitable for further
service without repair and replacement of parts.”
In other words, contact welding is allowed in the contactor and
overload burnout is acceptable. In either case, replacement of the control
components are required.
Type 2 Coordination on the other hand, limits the effect of a
short-circuit on the control components. Type 2 Coordination is defined as
follows:
“Under short-circuit conditions, the contactor or starter shall cause no
danger to persons or installation and shall be suitable for further use.
The risk of contact welding is recognized, in which case the manufacturer
shall indicate the measures to be taken in regard to the maintenance of
the equipment.”
Figure 8 illustrates the results of a short-circuit if a motor branch
circuit was protected by current limiting device vs. a circuit without a current
limiting device. In circuits using a current limiting device, the let-through
energy is limited to less than 1/2 cycle. This limited level of let-through
energy allows the control components to survive a short-circuit and continue
operation with little or no maintenance required.
In general, fuses have had much better current limiting capabilities
than do circuit breakers, although some current limiting circuit breakers can
provide Type 2 Coordination results. It is best to consult the control
manufacturer for recommended short-circuit protection devices required to
achieve Type 2 Coordination. Control manufacturers can provide component
selection data (see Table B) that has already been proven during Type 2
testing programs. By following the manufacturers guidelines, you can be
assured of achieving Type 2 Coordination in your motor branch circuit
installation.
Benefits of Type 2 coordination include:
• Increased productivity and less down time
• Reduced component replacement costs
• Simple selection of SCPDs and motor circuit components with
manufacturer supplied data

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“COORDINATED” MOTOR CIRCUIT PROTECTION

Figure 8
Let-through Heat and Current

Current
Peak available current (lp)
without current limiting fuse

NOT CURRENT-LIMITED

Normal
Load
Current Heat Energy

Time

Point
of Fault

Current
Peak available current (lp)
without current limiting fuse

CURRENT-LIMITED

Normal
Load
Current Heat Energy

Time

Point
of Fault

Fuse limits current less than 1/2 cycle

At the inception of a fault, a branch circuit can reach peak available current (lp) without a
current-limiting protector. The heat produced reaches temperatures that melt conductors as well
as insulation, and the magnetic forces bend conductors and supports. When protected with a
current-limiting fuse, however, the let-through current is only a fraction of lp, usually opening the
fuse in less than one-half cycle. Type 2 Coordination assures that no harm to people or damage
to equipment results from short-circuit currents.

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 “COORDINATED” MOTOR CIRCUIT PROTECTION

Table B
Manufacturer Fuse Recommendation for Type 2 Coordination
UL Listed Time-delay
Overload
Motor Horsepower Contactor Class J
Relay
(CSA HRCI-J) Fuse
Single Fuse
Three-phase Cat. No.
Phase Max.
Basic Amp. Gould-
115V 230V 200V 230V 460V 575V Rating Bussman Littlefuse
Cat. No. Cat. No. Shawmut
— — — — 1/2 3/4 100-A09 193-BSB16 2 LPJ-2 AJT2 JTD2
— — — — 3/4 1 100-A09 193-BSB16 2 LPJ-2 AJT2 JTD2
— 1/10 — 1/2 1 — 100-A09 193-BSB22 3 LPJ-3 AJT3 JTD3
— 1/8 — — — — 100-A09 193-BSB22 3 LPJ-3 AJT3 JTD3
— 1/6 1/2 — 1-1/2 1-1/2 100-A09 193-BSB30 6 LPJ-6 AJT6 JTD6
— — — — — 2 100-A09 193-BSB30 6 LPJ-6 AJT6 JTD6
1/10 1/4 3/4 3/4 2 — 100-A09 193-BSB42 6 LPJ-6 AJT6 JTD6
— 1/3 — 1 — — 100-A09 193-BSB42 6 LPJ-6 AJT6 JTD6
1/8 — — — — 3 100-A09 193-BSB50 6 LPJ-6 AJT6 JTD6
1/6 1/2 1 1-1/2 3 — 100-A09 193-BSB60 10 LPJ-10 AJT10 JTD10
1/4 3/4 1-1/2 2 5 5 100-A09 193-BSB80 10 LPJ-10 AJT10 JTD10
1/3 — — — — — 100-A09 193-BSB80 10 LPJ-10 AJT10 JTD10
— 1 2 — — 7-1/2 100-A09 193-BSC10 15 LPJ-15 AJT15 JTD15
— — — 3 — — 100-A12 193-BSC10 15 LPJ-15 AJT15 JTD15
1/2 1-1/2 3 — 7-1/2 10 100-A12 193-BSC15 20 LPJ-20 AJT20 JTD20
— 2 — — — — 100-A12 193-BSC15 20 LPJ-20 AJT20 JTD20
3/4 — — 5 10 — 100-A18 193-BSC15 20 LPJ-20 AJT20 JTD20
1 3 5 — — 15 100-A18 193-BSC24 30 LPJ-30 AJT30 JTD30
1-1/2 — — 7-1/2 15 20 100-A24 193-BSC24 30 LPJ-30 AJT30 JTD30
2 — — — — — 100-A24 193-BSC24 30 LPJ-30 AJT30 JTD30

By following manufacturer recommendation for maximum

short-circuit protection device allowed, automatic Type 2 Coordination can
be achieved.

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“COORDINATED” MOTOR CIRCUIT PROTECTION

MOTOR OVERLOAD PROTECTION

Overload relays are used in a motor circuit to protect motors and
circuit conductors from damage caused by prolonged periods of overcurrent
conditions. If motors are exposed to increased levels of continuous current
and prolonged periods at locked rotor condition, damage to the motor and
circuit conductors can occur.
Motors can be damaged or destroyed under any of the following
conditions.
• Low or high supply voltage
• Phase unbalance
• Continuous excessive loading
• Single-phasing
• Jam or stall conditions
• Ground/earth faults
• Mechanical failures such as seized motor bearing or binding
mechanical linkages
By selecting the proper type of overload relay with the appropriate
functionality, the motor can be protected from damage caused by these
conditions.

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 “COORDINATED” MOTOR CIRCUIT PROTECTION

TYPES OF OVERLOAD RELAYS

Today three basic types of overload relays are available: eutectic
alloy, bimetal, and solid-state. Let’s take a closer look at each type of
overload relay and review the basic features of each.

Eutectic Alloy Overload Relays

Eutectic alloy overload relays are typically used with NEMA motor
starters. These overload relays utilize a solder type alloy within heater
elements. As current moves through the heater element, the solder is heated
until a predetermined melting point (trip point) is reached. At the trip point,
the solder is instantaneously changed from a solid to a liquid, allowing the
ratchet mechanism to open a normally closed contact, dropping out the
starter coil circuit, Figure 9.

Figure 9
NEMA Type Eutectic Alloy Overload Relay

Eutectic Alloy
Heater

L1 T1
Ratchet
Pawl

To
Starter
Coil

Key features of a eutectic alloy overload relay:

• Tamper-proof
• Not effected by nuisance tripping caused by vibration
• Manual reset only
• Single-phase “sensitive”
• Selectable trip classes 10, 20, 30

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“COORDINATED” MOTOR CIRCUIT PROTECTION

Bimetal Overload Relays

Two types of bimetal overload relays are available, NEMA and IEC.
The NEMA type bimetal overload relay utilizes replaceable heater elements
that indirectly heat bimetal strips. As the bimetal strips are heated, they flex
towards a trip point, at which time a normally closed contact will open,
dropping out the starter coil, Figure 10.

Figure 10
NEMA Type Bimetal Overload Relay
Trip Bar Contacts

Heater
Element

Power Bimetal To
Circuit Strip Starter
Coil

Key features of a NEMA type bimetal overload relay:

• Flexibility of changeable heater elements.
• Automatic reset
• Selectable trip classes 10, 20, 30
• Ambient temperature compensation
• Single-phase sensitive

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 “COORDINATED” MOTOR CIRCUIT PROTECTION

Bimetal Overload Relays, Continued

IEC bimetal overload relays are similar to the NEMA devices except
that the heater/bimetal are integral to the overload relay, Figure 11. To allow
for added flexibility, the overload trip setting is adjustable over a range of
motor full load current settings. The typical FLA setting range would be
1.0:1.5 (min. to max. setting). IEC bimetal overload relays are typically
designed to Class 10 trip characteristics. This means that the overload relay
will trip in less than 10 seconds at locked rotor current.

Figure 11
IEC Type Bimetal Overload Relay

L1
L2
L3
Heater
Bimetal
Strip To
Starter
Coil
Trip Bar

Key features of an IEC type bimetal overload relay are:

• Manual or automatic reset
• Ambient temperature compensated
• Single-phase “sensitive”
• Wide current adjustment range (1:1.5)

Solid-state Overload Relays

Solid-state (electronic) overload relays are the newest and fastest
growing type of overload protection devices. Until recently, solid-state
overload relays were large, costly, and impractical for use on the vast
majority of small motors used in industry today. With recent development in
solid-state overload technology, the cost and size of the solid-state devices
have been significantly reduced while the functionality has been greatly
increased. The latest solid-state overload relay technology utilizes integral
current transformers, application specific integrated circuits (ASIC), and/or
microprocessors along with electromechanical design principles to produce a
compact, high functionality overload protection solution. Available in either
NEMA or IEC versions, the principle of operation is the same. As motor
current passes through the integral current transformers, power is available to
supply the integrated circuit. By monitoring the three-phase power, the
ASIC can process current data, and activate a trip mechanism on overload
conditions, opening a normally closed contact and dropping out the motor
starter coil circuit, Figure 12.

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 “COORDINATED” MOTOR CIRCUIT PROTECTION

ADVANCED MOTOR PROTECTION

As a result of integrating a microprocessor or an application specific
integrated circuit (ASIC) as the brains of a solid-state overload relay, the
opportunity to add advanced protective functionality to the overload relay
becomes very practical.

Figure 14
Advanced Overload Protection Devices

Besides “basic” overload protection, advanced solid-state overload

relay devices can offer additional functionality that previously would have
required several additional protection devices to be used in the motor circuit.
By consolidating many protective features into a single device, installation
costs, component costs, panel size, and maintenance time can be significantly
reduced while performance and efficiency of the system can be increased.
An additional benefit of solid-state devices is its ability to function
via network communications. Through a communication network, vital
motor information can be collected, processed and displayed in order to take
corrective action prior to reaching fault conditions. Examples of data that
can be obtained through the solid-state overload relay include:
• % Thermal capacity used (0–100%)
How close is the motor to a trip condition (100%)?
• Phase unbalance
• Average current
• FLA settings
• Fault frequency
• Fault cause indication
Through triac outputs, control via a communication network can
occur. Control functions include:
• Start/Stop
• Reset
• Restart limit
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“COORDINATED” MOTOR CIRCUIT PROTECTION

Table C
Advanced Solid-state vs. Traditional OLRs
Advanced Protection Feature Solid-state OLRs Traditional OLRs
D Jam/Stall protection selectable D Trips within .5 sec. at D Relays on overload trip
– I/O selectable 400% of FLA setting curve response
D Ground (earth) fault protection D Monitors phase vector D None – rely on SCPD
selectable angles
– I/O selectable Trips at lower level prior to
fault level
D Single-phase “protection” D Trips within two sec. on D “Sensitive” to single-
fully loaded motor phase conditions
Trips in 40 sec. or longer
D Trip setting accuracy D Dip switch setting D Potentiometer or heater
increased accuracy ±2.5% elements: ±10%
D Repeat accuracy of trip setting D Increased accuracy ±1% D ±5–10%
D LED trip indication D Fault cause indication D None
– Jam/Stall
– Ground earth fault
– Improper setting
– Communication loss
– Test
– Phase loss
– Overload

D Wide current adjustment range D 3.2:1 and 5:1 D 1.6:1 and 1.1:1
D Low power requirement and D 150mW per device D 6W or greater per device
low heat dissipation
D Trip classes 10, 15, 20, 30 D Selectable by DIP switch D Dedicated components per
setting trip class
D Network communications D Control, data acquisition D None
and fault cause indication
D Control
– Start/stop
– Reset
– Restart limit
D Data acquisition
– % thermal capacity
used (trip warning)
– Trip frequency
– Phase unbalance
– FLA trip setting
– Average current
D Fault cause indication
(see above)

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 “COORDINATED” MOTOR CIRCUIT PROTECTION

COORDINATED MOTOR CIRCUIT PROTECTION

Coordinated motor circuit protection for a branch circuit consists of
providing a continuous level of damage protection from minor overloads
through major short-circuit currents. Such protection provides benefits of
reduced down time and replacement costs as well as greater safety.
The purpose of the overload protection in any branch circuit is to
provide starting and running protection from overcurrents caused by such
problems as binding bearings or jammed parts in the machine. These
overcurrents range up to motor locked rotor current, usually about six times
the motor full load current. Since locked rotor current is also initial starting
current, overload protective devices require some designed in time delay in
order to prevent nuisance tripping during start up.
The time/current curve of an overload protective device shows that
the time to trip is inversely related to the magnitude of overload current.

Figure 15
Overload Response Curve

Time in
Seconds

1 2 3 4 5 6 7 8 9 10
Multiples of FLC

22
“COORDINATED” MOTOR CIRCUIT PROTECTION

The purpose of the short-circuit protective device is to prevent higher

levels of overcurrent from damaging components of the motor branch circuit.
Short-circuit currents are considered to range from motor locked rotor
current up to the maximum current available at the motor circuit
Short-circuit currents result from such problems as wiring errors,
insulation breakdown, and accidental contact with the circuit by tools or
other metal objects. Short-circuit protective devices must react quickly to
minimize damage.
The time/current curve for a short-circuit protective device shows its
trip timIt is also inversely related to current. You can see, however, that the
slope of the curve is very steep.

Figure 16
Short-circuit Protective Device Responsive Curve

Time in
Seconds

1 2 3 4 5 6 7 8 9 10
Multiples of FLC

23
 “COORDINATED” MOTOR CIRCUIT PROTECTION

The National Electrical Code requires short-circuit and overload

protection for the branch circuit. If these curves are overlaid we then have a
time current curve that illustrates the behavior of the protective devices for
all levels of current. If the curves intersect, the point of intersection is called
“coordination point.” This point should be just above motor locked motor
current (6–8  FLC) for proper coordination. If the curves are properly
coordinated, the short-circuit protective device will react to currents above
the overload range, but will not trip if the overcurrent is in the overload
range.

Figure 17
Coordinated Motor Circuit Protection
Short-circuit
Protective Devices

Overload
Relay

COORDINATION
Time in POINT
Seconds

Motor Branch Circuit

Motor Running Short-circuit Protection
Overprotection Protection

1 2 3 4 5 6 7 8 9 10
Multiples of FLC

24
“COORDINATED” MOTOR CIRCUIT PROTECTION

If, however, these curves do not intersect, or intersect well above the
motor locked rotor current, the overload protective device will react to
short-circuit currents in the gap between the overload range and short-circuit
protection, and probably be damaged.

Figure 18
Protection Not Coordinated (Curves Do Not Intersect)

Overload Short-circuit
Relay Protective Devices

Time in
Seconds

1 2 3 4 5 6 7 8 9 10
Multiples of FLC

If the curves intersect in the overload range below the locked rotor
current, the short-circuit protective device will nuisance trip on motor
start-up.
Figure 19
Protection Not Coordinated (Curves intersect at less than locked rotor current)

Overload
Time in Relay
Seconds

Short-circuit
Protective Devices

1 2 3 4 5 6 7 8 9 10
Multiples of FLC
25
 “COORDINATED” MOTOR CIRCUIT PROTECTION

LIFE OF A TYPICAL MOTOR INSTALLATION

Over the life of a typical motor installation, several different fault
conditions can occur, from high level faults such as short-circuits or ground
faults to low level faults such as overloads and jam conditions. When
selecting motor circuit protection devices, several questions should be raised.
• Is the motor circuit critical to the manufacturing process?
• What is the “total cost” of downtime in the application?
• Is the application more susceptible to certain types of fault
conditions?
• Is Type 2 Coordination important?
• Do I need to collect motor data and be warned of impending fault?
• Are fuses or circuit breakers preferred for short-circuit protection?
Dependent on the answers to these questions (and possibly many
others), the process can begin to specify the type of products required to
adequately protect the motor circuit. For less critical applications such as a
fan or blower, where critical manufacturing processes or safety issues are not
a consideration, meeting code requirements with fuses and a traditional
overload relay may be the ideal solution. On the other hand, in a critical
application, where the manufacturing process relies on a continuous flow of
materials and downtime can be very costly, the best protection solution may
require the following capabilities:
• Selecting a short-circuit protection device that provides Type 2
Coordination
• Selecting a solid-state overload device that provides:
– Ground fault protection
– Jam/Stall protection
– Network communications to more closely monitor the motor data
and application
By properly outlining the application requirements and selecting the
appropriate protection components, the optimum implementation costs and
motor circuit protection scheme can be developed to optimize the maximum
life and performance of the motor and application.

26
 “COORDINATED” MOTOR CIRCUIT PROTECTION

Figure 20
Life of a 40 HP Motor

Crusher Application
40 HP Motor (50A FLC)

Ie

100,000

50,000

10,000

5,000

1,000

500

100 WARNING!

Motor 100%
FLA 50
2 Sec. 40 Sec. 1/2 Sec. 15 Sec.
0 Time
Short- Ground/
Fault Type Circuit Earth Overload Phase Loss Jam/Stall Impending Trip

Fuses
or
Circuit Breakers

Protection Traditional Overload Responds with

Device Protection Devices Overload Trip Curve
Type

Advanced Protection via

Trip Due Network Communications
to Low D % Thermal Capacity used
Level Solid-state Overload Protection Devices
D Phase Unbalance
Ground D Start-Stop-Reset Control
Fault D Restart Limit

High Level Low Level Faults

Faults

“Coordinated“
Motor Circuit
Protection Point

27
 “COORDINATED” MOTOR CIRCUIT PROTECTION

TERMINOLOGY
To help understand Coordinated Motor Circuit Protection, it is
necessary to be familiar with the characteristics and definitions related to
fuses, circuit breakers, overload relays, short-circuit, and overload protection.
• Ampere Rating – The continuous current carrying capability of a fuse or
circuit breaker.
• Ampere-squared Seconds (I 2t) – An expression related to the thermal
energy associated with current flow.
• Available Fault Current – The maximum possible short-circuit current
that can flow in an unprotected circuit.
• BS88 Fuse Designations – British Standards Institute has defined basic
physical specifications (size, mounting dimensions, labeling) and
guidelines to fuse manufacturers for providing maximum let-through
current and energy for fuses (in a standard format). Fuse designed to
British Standards are described by their dimension (e.g., Al, A2, A3, A4,
B1, etc.) and continuous current rating.
• Circuit Breaker – A device designed to open and close a circuit by
non-automatic means and to open the circuit automatically on a
predetermined overload current.
• Clearing Time – The total time measured from the beginning of the fault
to the interruption of the circuit.
• Current Limiting Circuit Breaker – A circuit breaker that does not
employ a fusible element and that when operating within its current
limiting range, limits the let-through I2t to a value less than the I2t of a 1/2
cycle wave of the symmetrical prospective current.
• Current Limiting Fuse – A fuse which will limit both the magnitude and
duration of current flow under short-circuit conditions. The available
fault currents a fuse will clear in less than 1/2 cycle, thus limiting the
actual magnitude of current flow.
• DIN Fuse Designations – DIN/VDE Standards specify physical
specifications as well as classes of operation for fuses. The class of
operation is identified by two or three letters (e.g., gL, aM, gTr). The gL
fuse is a general purpose fuse with characteristics that are well suited for
the protection of starters and associated wiring. These fuses are described
by their dimension (e.g., 00, 0, 1, 2, 3 and 4) and continuous current
rating.

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“COORDINATED” MOTOR CIRCUIT PROTECTION

• Dual-element Time Delay Fuse – A fuse of special design which

utilizes two individual elements in series inside the the fuse casing. One
element is a spring-actuated trigger assembly that operates that operates
on sustained overloads, but which ignores momentary surges. The other
element operates without intentional delay on currents of fault magnitude
up to the interrupting rating of the fuse.
• Fast-acting Fuse – A fuse that opens very quickly on currents of fault
magnitude. This type of fuse is designed with no intentional time-delay
characteristics. Fast-acting fuses are commonly used to protect solid-state
electronic devices.
• Fuse – An overcurrent protective device with a fusible link that operates
to open the circuit on an overcurrent condition.
• High Level Fault – Short-circuit currents between the threshold current
of a fuse that would be used for the branch circuit protection of a motor in
a given application and the test current for the controller of that motor, per
the short-circuit test of UL 508.
• Interrupting Rating – The maximum short-circuit current that an
overcurrent protective device can safely open or clear.
• Let-through Energy (I 2t) – A measure of thermal energy developed
within a circuit during the total clearing time of the fault current.
• Low Level Fault – Short-circuit currents that are less than the threshold
current of a fuse that would be used for the branch circuit protection of a
motor in a given application.
• Overcurrent – A condition existing in an electrical circuit when normal
current is exceeded. Overcurrents occur in two distinctly separate forms
– overloads and short-circuits.
• Overload – An overcurrent that exceeds the normal full-load current of a
circuit.
• Overload Current – A level of current above the motor full load current,
but generally not greater than six times the full load current. Overload
currents are usually caused by overloading the motor and are restricted to
the normal current path. These currents are typically detected by the
overload relay.
• Peak Let-through Current (Ip) – The maximum instantaneous peak
current passed through a short-circuit protective device when clearing a
fault current of specified magnitude.
• RMS Current – The effective, root-mean square value of current, and
the measure of its heating effect. The RMS value is calculated as the
square root of the mean of the squares of all the instantaneous values of
the current throughout one cycle. RMS alternating current is the value of
an alternating current that produces the same heating effect as a given
value of direct current.
• Short-circuit Current – Excessive current caused by insulation
breakdown or wiring error. Short-circuit currents leave the normal
current carrying path of the circuit, such as line-to-line or line-to-ground.
Short-circuits are typically detected and cleared by the branch circuit
protective devices.

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 “COORDINATED” MOTOR CIRCUIT PROTECTION

• Single-phasing – The condition that exists when one phase of a

three-phase power system opens. Single-phasing results in unbalanced
currents and overheating in polyphase motors and other three-phase
inductive devices. Proper selection of dual-element time-delay fuses
and/or protective relays will help protect motors from damage during
single-phasing conditions.
• Threshold Current – The magnitude of current a which an SCPD
becomes current limiting.
• Time-delay Fuse – A fuse with a built-in time delay that allows
temporary a harmless inrush currents to pass without opening, but is
designed to open on sustained overloads and currents short-circuit
magnitude.
• UL Class of Fuse/CSA Fuse Designations – Underwriters Laboratories
and the Canadian Standard Association have developed basic physical
specifications (size, rejection features, labeling) and electrical
performance requirements (interrupting rating, maximum Ip and I2t) for
fuses with voltage ratings of 600 volts or less. If a fuse meets these
requirements, it can be designated by a UL class of fuse or a CSA fuse
designation. Typical UL fuse classes are K1, K5, RK1, RK5, J, T, and
CC. Typical CSA fuse designations are HRCI-T HRCI-R, HRCI-J, and
HRCII-C.
• Voltage Rating – The maximum value of system voltage in which a fuse
can be used and safely interrupt an overcurrent. Exceeding the fuse
voltage rating impairs its ability to clear an overload or short-circuit
safely.

30
 Allen–Bradley is committed to supporting you throughout
each phase of the Automation Investment Life Cycle.
Allen–Bradley offers a wide range of motor protection products that
will help extend the life of your motor. These products are an integral
part of the automation process and the life cycle.
Justify. If your application requires motor protection, choose any
one of our solutions for increased productivity. These product lines
offers many protective features such as detection of overload, short
circuit and ground fault conditions. Analyze the complete line of mo-
tor protection products through customer training seminars, product
demonstrations and literature.
Apply. Any one of the motor protection devices may be applied
based upon your application and requirements. Many of these prod-
ucts work together to provide increased functionality.
Install. Integrate our products with new systems as well as existing
systems. Traditional and solid–state protection is available. Our pan-
el system solution reduces wiring and installation costs.
Operate. Striving for optimum productivity and monitoring motor
faults constitute pro–active approaches to this phase.
Maintain. By protecting the motor from damage, our products help
reduce downtime. Product features such as diagnostics and commu-
nications capability also reduce system maintenance.
Improve. Extending the life of your motor is the main benefit of our
product line. As your needs change, we change with you by increas-
ing the effectiveness of our products and monitoring market demands.
Staying focused on product line improvements results in advanced
product offerings such as the SMPTM Overload Relays and the Smart
Motor Manager.

The Automation Investment Life Cycle graphic and SMP are trademarks of the
Allen–Bradley Company.

Publication 193–2.10 July 1995

Copyright 1995 Allen-Bradley Company, Inc., a Rockwell International company Printed in USA
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