IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 34, NO.

4, JULY/AUGUST 1998 697

Application Guidelines for Instantaneous-Trip

Circuit Breakers in Combination
Motor Starters
George D. Gregory, Senior Member, IEEE, and Lorraine K. Padden, Senior Member, IEEE

Abstract— This paper addresses the application of instan-

taneous-trip molded-case circuit breakers (MCCB’s) in combi-
nation motor starters. These circuit breakers have been widely
used in many industries for motor circuit protection. If they
are not properly applied, situations of false tripping on motor
starting and contact welding of contactors under low-level faults
may occur. Energy efficiency motors compound the issue of false
tripping on motor starting. This paper discusses the components
of combination starters, reviews testing requirements, and pro-
vides examples of coordination with analysis of application issues
and solution options.
Index Terms— Combination motor starter, instantaneous-trip
molded-case circuit breaker, low-voltage protection.

I. OUTLINE OF ISSUES
Fig. 1. Combination motor starter components.

T HE following questions will be discussed in this paper.

• What is a combination starter?
• How are components and the combination starter tested
and rated?
• What are selection factors for components?
• What is the bandwidth of a circuit breaker setting?
• How can false tripping during starting be avoided?
• How can contact welding of contactors be mitigated?
II. DESCRIPTION OF A COMBINATION STARTER
ANSI/UL Standard 508-1993, Industrial Control Equip-
ment, defines a combination controller as “an open or enclosed
device containing both a magnetic or solid-state controller and
a disconnecting means. The controller may or may not contain
overload protection, short-circuit protection, or both. Where an
individual controller is enclosed, it includes an external means
for operating the disconnecting means.” [1] Then, it defines
a combination motor controller as “a combination controller
intended for motor service.” A combination starter is one
form of a combination motor controller and is supplied as
an individually enclosed unit or as an individual unit to be
installed in a motor control center.
Relating these definitions to Section 430-52(c)(3) of the Na-
tional Electrical Code (NEC), combination starters, in which
Paper ICPSD 97–39, presented at the 1997 Industry Applications Society
Annual Meeting, New Orleans, LA, October 5–9, and approved for publication
in the IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS by the Power Systems
Protection Committee of the IEEE Industry Applications Society. Manuscript
released for publication February 23, 1998.
G. D. Gregory is with Square D Company, Cedar Rapids, IA 52404 USA.
L. K. Padden is with Padden Engineering, LLC, Katy, TX 77491 USA.
Publisher Item Identifier S 0093-9994(98)04922-6.
0093–9994/98$10.00  1998 IEEE
an instantaneous-trip circuit breaker is used, contain at least an
overload relay, a controller (contactor), and the circuit breaker.
A combination motor controller is marked with ratings of
voltage and horsepower and will generally have a short-circuit
current rating. Different horsepower and short-circuit current
ratings may be linked with different voltages.
III. COMPONENTS
It is helpful to understand the components as they are
outlined in the NEC. Fig. 1 diagrams components that may
be in a combination motor starter unit. Fig. 430-1 of the NEC
is also a convenient reference [2].
Combination starters perform the following four basic func-
tions:
• conducting;
• switching (disconnecting and controlling);
• overload (thermal) protection;
• short-circuit and ground-fault protection.
The components are discussed in terms of their functions.
A. Conducting
Branch-circuit conductors supplying a single motor are
required to have ampacity not less than 125% of the motor
full-load current (FLC) rating under NEC Section 430-22 [2].
B. Disconnecting Means
The motor disconnecting means is a switching device. NEC
Section 430-109 is quite specific concerning the devices that
698 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 34, NO. 4, JULY/AUGUST 1998
may serve this function, stating that it shall be a motor-
circuit switch rated in horsepower, a circuit breaker, or a
molded-case switch, and shall be a listed device [2]. A manual
motor controller is not permitted for this application. By
exception, an instantaneous-trip circuit breaker may serve as
the disconnecting means only if it is part of a listed combina-
tion motor controller. Other exceptions permit other devices
under specific conditions. NEC Section 430-110 requires the
disconnecting means to have a continuous current rating of at
least 115% of the FLC of the motor [2].
C. Controller
As defined in NEC Section 430-81(a), “a controller is any
switch or device normally used to start and stop a motor by
making and breaking the motor-circuit current.” [2] It is a
switching device capable of starting and stopping the motor
it controls and capable of interrupting the locked-rotor current
(LRC) of the motor. In many cases, the controller is a contactor
rated in horsepower. An inverse-time circuit breaker is also
permitted to serve as a controller, but an instantaneous-trip
circuit breaker is not, under the present NEC [2].
D. Overload Protection
Motor overload protection is required to protect motors,
motor-control apparatus, and branch-circuit conductors against
excessive heating (thermal protection) due to motor overloads
and failure to start. Permanently installed motors are protected
by either an overload relay or by a thermal protector or
protective device integral with the motor. Overload relays
are installed in the combination motor starter units when
instantaneous-trip circuit breakers are used.
E. Short-Circuit and Ground-Fault Protection
The branch-circuit short-circuit and ground-fault protection
is intended to protect the branch-circuit conductor, the motor
control apparatus, and the motor against overcurrent due to
short circuits or ground faults. The device may be a listed
fuse or a listed inverse-time circuit breaker. An instantaneous-
trip circuit breaker is permitted only if adjustable and if part
of a listed combination motor controller. Overload protection
is provided by other components in the circuit.
IV. INSTANTANEOUS-TRIP CIRCUIT BREAKERS
A. Circuit Breaker Function
In the above discussion, it is clear that a circuit breaker in
a motor branch circuit serves the dual functions of disconnect
switch and short-circuit protection. Other devices provide
thermal overload protection.
B. Thermal-Magnetic Molded-Case Circuit
Breaker (MCCB) Contrast
The most commonly available MCCB is thermal-magnetic.
A typical thermal-magnetic MCCB characteristic appears in
Fig. 2. A thermal-magnetic breaker’s inverse-time function
Fig. 2. Time–current characteristic for a 150-A adjustable trip ther-
mal-magnetic MCCB.
can provide the thermal overload protection if sized in ac-
cordance with NEC Section 430, Part C, but, in most cases,
provides backup protection for a thermal overload relay, such
as that shown in Fig. 1 [2]. Smaller current rated thermal-
magnetic MCCB’s typically have fixed instantaneous-trip set-
tings at about 10–20 rated current, whereas the larger cur-
rent rated thermal-magnetic breakers may have the adjustable
instantaneous-trip settings that typically range from 5–10
the continuous current rating of the MCCB. The availability
of the adjustable features depends on the manufacturer.
Like the instantaneous-trip breaker, the thermal-magnetic
breaker can be used as the disconnect and as the short-
circuit protection, but, in addition, can also provide overload
protection.
C. Instantaneous-Trip Characteristic
The instantaneous-trip circuit breaker is essentially a
thermal-magnetic circuit breaker with the thermal sensing
element removed. Its characteristic appears in Fig. 3. The
instantaneous sensing element, usually an electromagnet, has
an adjustable setting that can be adjusted to the needed trip
value.
MCCB’s exhibit a band of tripping current for any given
instantaneous-trip setting. According to UL Standard 489,
Molded-Case Circuit Breakers, Molded-Case Switches, and
Circuit-Breaker Enclosures, the trip range tolerance is as
indicated in Table I [3]. A considerably tighter degree of
precision exists with electronic trip units; however, there is
no industry standard for a tolerance closer than that in Table I.
D. Ratings
Instantaneous-trip MCCB’s are available in continuous cur-
rent ratings from 3 to 1200 A. The instantaneous setting can
typically be adjusted in fixed steps to between about 3–11
the continuous current rating. The settings are calibrated
GREGORY AND PADDEN: INSTANTANEOUS-TRIP CIRCUIT BREAKERS IN COMBINATION MOTOR STARTERS
Fig. 3. Time–current characteristic for a 150-A instantaneous-trip MCCB.
TABLE I
TRIP TOLERANCES FOR INSTANTANEOUS OPERATION
and marked in rms terms, although the sensing mechanism
is usually an electromagnet, which is actually sensing peak
current.
An instantaneous-trip circuit breaker is rated in continuous
current and volts. It is not permitted to have a marked
interrupting rating as a means of distinguishing it from the
listed circuit breaker intended for branch-circuit protection.
The instantaneous-trip circuit breaker is “Component Rec-
ognized” by Underwriters Laboratories (UL), rather than being
“Listed.” The optional marking of a backward “UR” symbol
on the product may indicate this recognition. “Component
Recognition” indicates that the product is incomplete in some
condition, a condition that will be completed when the product
is installed in “Listed” equipment for which use it has been in-
vestigated. In this case, the instantaneous-trip circuit breaker is
made complete by installing it in a “Listed” combination motor
controller in compliance with NEC Section 430-52(c)(3). [2]
This NEC section requires that the combination have coordi-
nated overload, short-circuit, and ground-fault protection in
each conductor. Combination starter units and combination
motor control units used in motor control centers are two
examples of combination motor controllers.
As a component recognized device intended for use in a
combination unit, the only short-circuit current rating applied
is the rating applied to the combination unit. Because of mis-
application occurrences of instantaneous-trip circuit breakers,
the industry has been reluctant to add interrupting ratings on
699
instantaneous-trip MCCB’s. However, manufacturers may be
able to provide interrupting rating information about these
products, if it is needed.
E. Testing of Instantaneous-Trip Circuit Breakers
Under UL Standard 489, an instantaneous-trip circuit
breaker is required to complete overload, temperature, and
endurance testing identical to that to which a “Listed” circuit
breaker is subjected and with identical performance criteria
[3]. Calibration testing is done on each pole of each tested
sample before and after each test sequence to verify tripping
within Table I tolerances. Dielectric withstand testing is also
done following each test sequence.
A short-circuit interrupting test is done as for the “Listed”
circuit breaker at standard-level limited available current. In
this test a trip coil is permitted to burn out. However, if a trip
coil burns out, a second set of samples is subjected to a repeat
of the short-circuit test with an impedance equivalent to that
of an overload relay, in which test the trip coil may not burn
out. For three-pole circuit breakers up to 800 A rated 480 or
600 V, this test consists of two short circuits on each pole
with 8660 A available at line-to-line voltage and a common
three-phase short circuit with 10 000 A available. These seven
short-circuit operations are followed by a calibration and a
dielectric withstand test.
V. COMBINATION MOTOR CONTROLLER TESTS
Refer to Fig. 1 for components. Component tests of the
circuit breaker were discussed above. The contactor and relay
will each be tested as a component under ANSI/UL Standard
508 [1]. Then, the combination is subjected to the following
tests:
• temperature;
• dielectric withstand;
• current withstand;
• contactor overload;
• combination short circuit;
• high available short-circuit current.
For the current withstand test and all short-circuit tests, a
wide range of combination controller samples are tested to
cover the possible combinations of overload relays, current
elements, and instantaneous-trip circuit breaker trip coils.
A. Temperature Test
The combination controller is required to carry FLC contin-
uously and retain temperatures compatible with materials and
components used in its construction.
B. Current Withstand Test
The combination controller is required to carry 600%, and
then 1000%, of FLC without damage to parts or connected
wire that would impair their function. The test is continued
until the circuit is opened by the overload relay. The circuit
breaker trip setting is adjusted to maximum or its mechanism
is impaired to prevent tripping during the test.
700 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 34, NO. 4, JULY/AUGUST 1998
TABLE II
COMBINATION SHORT-CIRCUIT TESTS
C. Contactor Overload Test
A magnetic or a vacuum contactor is required to break
1000% of maximum FLC at maximum rated voltage and
50% power factor for three operations under conditions of
maximum voltage, power, and current for each rating of
the combination controller. During the test, the contactor is
required to break the circuit without mechanical or electrical
breakdown and without contact weld.
D. Combination Short-Circuit Test
Each combination controller is subjected to a specified
short-circuit level corresponding to its horsepower rating.
These are shown in Table II. Connection wire is sized to
at least 125% of the FLC rating of the current element. On
the supply side, 4 ft of wire connect the unit to test station
terminals, and an additional 4 ft of wire on the load side
connect the unit to the short-circuit point. The circuit breaker
is adjusted to its maximum setting. The number of short-circuit
operations varies and is shown in Table II.
Criteria for acceptance include the following points. The
circuit breaker or contactor must clear the circuit. The circuit
breaker must retain its integrity and demonstrate compliance
with calibration and dielectric withstand testing following all
short-circuit operations. The contactor and overload relay may
be inoperative, but insulating material must remain intact, such
that live parts are not exposed and parts may not be expelled
from the housing. Contacts of a contactor may weld or may
disintegrate. Conductors may not be damaged and may not
pull out of connectors. The unit must satisfactorily complete
a dielectric withstand test following short-circuit testing.
E. High Available Short-Circuit Current Test
This is an optional test for units to obtain a short-circuit
current rating above that in the combination short-circuit
test. The test procedure is quite similar. Two short-circuit
operations are conducted on each unit: 1) an “O” (open)
operation in which the test circuit is closed on the unit under
test by a test station device on the supply side of the unit and 2)
a “CO” (close–open) operation in which the instantaneous-trip
circuit breaker is closed on the test circuit. The contactor will
be closed prior to the test in each case using a separate supply.
Criteria for acceptance is the same as in the combination
short-circuit test.
Let us clarify that a contactor is tested in an overload test up
to 10 FLC in which it must clear the circuit. For coordination
purposes, be aware that contacts may weld under current levels
above 10 FLC.
VI. COMPONENT SELECTION
A. Overload Relay Selection
To comply with NEC 430-32(a)(1) and (c)(1), an overload
relay is selected to trip at no more than the following percent
of nameplate full-load rating:
• motors with a marked service factor not less than 1.15,
125%;
• motors with a marked temperature rise not over 40 C,
125%;
• other motors, 115%.
When used in a combination controller, the relay’s short-
circuit current rating is the integrated rating of the combination
unit.
The most common practice is for the overload relay to
be wired such that the contactor opens during an overload
condition.
B. Circuit Breaker Selection
The following three factors must be considered when se-
lecting an instantaneous-trip circuit breaker.
• The continuous current rating must be 115% or greater
of motor FLC to comply with NEC Section 430-110(a)
when the breaker is also used as the disconnect.
• The adjustable trip range must comply with Table 430-
152 of the NEC, that is, it must be no more than 800%
of FLC for other than Design E motors and 1100% of
FLC for Design E motors. Further, if starting current will
cause it to trip at these settings, it may be adjusted to a
higher setting to avoid nuisance operation, as long as the
need has been demonstrated by engineering evaluations.
The maximum permissible adjustment to avoid nuisance
operation under NEC Section 430-52(c)(3) is 1300% of
FLC for other than Design E motors or 1700% of FLC for
Design E motors [2]. The NEC does not allow for higher
settings, even if the motor still experiences nuisance
tripping. The instantaneous-trip breaker design will not
block settings above that allowed by the NEC. Therefore,
it is important to convey to operators/electricians what
the maximum setting is for each application.
• Wire connectors must be suitable for the conductors to
which they will be connected, if wire is to be connected.
Using the example of the motor circuit for the 100-hp
460-V motor as above, the instantaneous-trip circuit breaker’s
continuous current rating must be 115% of FLC (115% of
124 A) or 143 A minimum. The next standard current rating
is 150 A. It must have an adjustable setting of no greater
than 800% of FLC (992 A) if other than a Design E motor
and 1100% of FLC (1364 A) if a Design E motor to comply
with NEC Table 430-152. It may need higher settings if the
asymmetrical starting current is determined to be greater than
GREGORY AND PADDEN: INSTANTANEOUS-TRIP CIRCUIT BREAKERS IN COMBINATION MOTOR STARTERS
the setting allowed by Table 430-152 (including the device
bandwidth). Wire connectors must be suitable for the no. 2/0
AWG conductors if they are brought to the circuit breaker.
The instantaneous-trip circuit breaker will not have an inter-
rupting rating. A short-circuit current rating is instead applied
to and marked on the combination starter unit containing the
circuit breaker. The design engineer must determine that the
combination starter short-circuit current rating is adequate for
the system in which it is used. The combination starter is short-
circuit retested every two years under UL’s Follow-Up Service
to ensure that the rating is retained by all components [1].
The “80% rule” and the “100% rating” applied to certain
thermal-magnetic and electronic circuit breakers does not
apply to motor circuits. The “80% rule” comes from NEC
Sections 210-22(c), 220-3(a), and 220-10(b) which contain the
requirement that an overcurrent protective device be rated not
less than the noncontinuous load plus 125% of the continuous
load. In other words, the continuous load will be no more than
80% of the rating of the device. For branch and feeder circuits
other than motor circuits, this 100% rating is permitted by
exceptions to the same NEC sections. The 100% rating implies
that the circuit breaker is capable of continuous operation at
100% of its rated current while enclosed, without operating
automatically to open the circuit and without experiencing an
excessive temperature condition.
C. Contactor Selection
A contactor used as the motor controller is required to have
a horsepower rating at the application voltage not less than
the horsepower rating of the motor. For a Design E motor,
the contactor must either be marked as suitable for Design E
motors or have a horsepower rating 1.4 that of a 1–100-hp
motor or 1.3 that of a motor over 100 hp. The reader is
referred to NEMA Standard ICS-2 for a tabulation of various
types and sizes of contactors [4].
When used in a combination controller, the contactor’s
short-circuit current rating is the integrated rating of the
combination unit.
If the overload relay is wired such that the contactor
opens on overload conditions, the make/break capability of
the contactor should be reviewed for coordination with the
short-circuit protection device.
D. Conductor Selection
Conductors are selected in accordance with the motor cir-
cuit ampacity by applying NEC Sections 430-22–430-24 [2].
Where a single motor is involved, the conductors are required
to have an ampacity of not less than 125% of FLC using NEC
Tables 430-148–430-150 and not the nameplate FLC (unless
the nameplate FLC is higher than the Table values, such as
1200-r/min motors). Conductors are then selected for their
ampacity, using NEC Section 310-15. The most commonly
applied ampacity table is Table 310-16. Correction factors for
ambient temperature and deration factors for the number of
conductors in a cable or raceway may need to be applied [5].
When determining the correct cable ampacity, it is essential
to be aware of equipment wire connector temperature limita-
701
tions. For example, circuit breakers, contactors, and overload
relays are not suitable for connection of 90 C conductors at
90 C ampacity. The equipment will be marked to identify
suitable conductors by wire size, conductor metal (Cu or Al),
and insulation temperature, which will not be over 75 C.
Conductors rated 90 C may be used as long as their ampacity
at 75 C or 60 C, as marked on the product terminals, meets
the NEC current requirements. Note that conductor correction
factors and deration factors are applied to the ampacity based
on the insulation rating (e.g., 90 C). The conductor must also
fit the wire connector provided on the equipment [5].
When a power factor correction capacitor is provided,
as indicated in Fig. 1, its effect is to be disregarded when
determining the ampacity of the motor-circuit conductors.
Ampacity of the conductors to the capacitor are to be the
larger of 135% of the rated current of the capacitor or 1/3 of
the ampacity of the motor circuit conductors.
Consider a 100-hp 460-V motor example. FLC is 124 A
from NEC Table 430-150. The required ampacity is 125% of
124 A, or 155 A. Using Table 310-16 , a no. 2/0 AWG copper
cable with a 175-A ampacity is required, assuming a 75 C
termination rating (no correction factors or deration factors
are applied). A coordination plot shows the thermal damage
curve of the conductor. The conductor must be protected by
the overload and short-circuit devices.
VII. COORDINATION DISCUSSION
The two components of coordination are as follows:
• protection;
• selectivity.
NEC Section 110-10 addresses the protection requirements:
“The overcurrent protective devices, the total impedance, the
component short-circuit withstand ratings, and other charac-
teristics of the circuit to be protected shall be selected and
coordinated to permit the circuit protective devices used to
clear a fault to do so without extensive damage to the electrical
components of the circuit.” [1] The combination motor starter
protective devices should also be selective with devices on
the supply side.
According to ANSI/UL Standard 508, the phrase
“ without extensive damage ” means that the circuit
is cleared without fire or shock hazard. Components must
retain structural integrity, such that live electrical parts are
not exposed and will pass a dielectric withstand test following
a short-circuit test [1].
A. Coordination Example
Refer to Fig. 4 for the time–current plot of a coordination
example.
The parameters are as follows:
motor—100 hp, 460 V, Design B;
MCCB—175 A instantaneous trip;
MCCB setting—12 FLC 1500 A;
overload—class 10;
contactor—NEMA size 4;
conductor—no. 2/0 AWG XHHW, Cu;
available short circuit—20 000 A.
702 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 34, NO. 4, JULY/AUGUST 1998
Fig. 4. Time–current coordination plot for a 480-V 100-hp motor showing
the unprotected area of the contactor.
For the circuit breaker setting, the following analysis is used.
• Consider the maximum permissible setting for a Design
B motor of 800% of FLC (8 124 A 992 A) in NEC
Table 430-152.
• Determine whether false tripping is expected when start-
ing. A typical asymmetrical starting current is assumed
and calculated as follows: 1.76 LRC (1.76 725
1276 A) in rms terms [5]–[8]. This indicates false tripping
will occur with the 800% setting.
• Using NEC Section 430-53(c)(3) Ex 1, it is permissible
to adjust the setting higher than 800%, but no higher than
1300% (13 124 A 1612 A) for the Design B motor.
• A setting of 12 FLC was chosen for this example to
review possible false tripping and view interaction with
other components.
B. Coordination Issues
1) False Tripping and Contactor Rating: Finding an ap-
propriate circuit breaker setting that will permit starting current
to flow while providing protection for the contactor may be
a challenge. Asymmetrical starting current can be several
times LRC. Recall that the circuit breaker settings are marked
in rms terms. For this example, the asymmetrical starting
current was calculated at 1276 A, which would occur in
the first half cycle. The size-4 contactor has been tested to
break up to 10 its continuous current rating of 135 A, or
1350 A. It would seem that a setting of 1300 A would be
satisfactory to permit starting current to flow while protecting
the contactor.
The circuit breaker tripping band must be considered. Using
Table I, the tripping band for a setting of 1300 A would be
1040–1690 A. Operation at the low end of the band could see
false tripping on starting. At the high end, the contactor might
open above its tested break current on a high-impedance fault,
and a contact weld is possible.
A setting of 1500 A was selected for Fig. 4 to illustrate a
high setting available on a typical breaker without exceeding
the NEC limit. This selection still leaves a gap in which the
contactor is unprotected and overlaps a small range in which
the breaker could trip during motor start.
An asymmetrical starting value of 1.76 the LRC is a
typical value used for industrial applications [5]–[8]. This
condition illustrates the coordination issues that arise for
industrial applications. In some cases, the multiplier will be
lower. However, with the advent of energy-efficient motors,
high starting current issues are increasing.
C. Potential Solutions
If false tripping during start still occurs when the
instantaneous-trip setting is at the maximum allowed by the
NEC, several options should be considered.
• Use a thermal-magnetic MCCB or fuse in place of the
instantaneous-trip MCCB. Fixed-trip thermal-magnetic
MCCB’s have an instantaneous-trip range higher than
the instantaneous-trip MCCB, thereby allowing the mo-
tor to start. Ratings of the contactor and other compo-
nents should be reviewed for protection. Adjustable-trip
thermal-magnetic breakers may provide the best of both
worlds, allowing a higher instantaneous setting within
the NEC requirements, while providing the maximum
possible protection for other components, such as the
contactor. As the design engineer would expect, the
instantaneous-trip devices are the least expensive, the
fixed-trip thermal-magnetic breakers are more expensive,
and the adjustable-trip thermal-magnetic breakers are the
most expensive.
• Use an MCCB with time delay or damping to override
starting current.
• Use a reduced-voltage starter, such as an autotransformer,
during starting to reduce the starting current.
An option to avoid applying the contactor at levels above
those for which it has been tested to break is to specify a
larger contactor which has a higher current rating. Contactors
are tested to break current at 10 their continuous rating.
Therefore, the contactor would be protected with a higher
setting of the instantaneous-trip MCCB (within the NEC
requirements).
If space is a factor in upsizing the contactor, vacuum
contactors should be considered. They are manufactured with
FLC ratings of 160, 320, 600, and 720 A and have a break
rating of 10 FLC. These are generally smaller in size than
the comparable magnetic contactor, but are more expensive. A
cost/benefit analysis may be needed to determine the contactor
type.
Fig. 5 explores one of these solution options. A size-5
contactor is illustrated with an instantaneous-trip setting of
1610 A. Note that the NEC permits 13 FLC for the setting,
which would be 1612 A. The maximum trip is 1610 130%,
GREGORY AND PADDEN: INSTANTANEOUS-TRIP CIRCUIT BREAKERS IN COMBINATION MOTOR STARTERS
Fig. 5. Time–current plot for a 480-V 100-hp motor showing the protected
contactor.
or 2093 A. The minimum trip is 1610 80%, or 1288 A. For
this case, the size-5 contactor is protected using a trip setting
of 1610 A, because the contactor break rating of 2700 A is not
exceeded. Also, the circuit breaker should not trip on motor
start, because the minimum trip is 1288 A, which is above the
asymmetrical starting current of 1276 A.
This solution satisfies the protection criteria. Because of
high starting current, protection of the motor is not as close
as might be desired. Also, selective coordination with devices
on the supply side will be more of a challenge than with a
lower setting.
D. Backup Protection
The design engineer should evaluate the need for backup
protection in the overload region. First, the overload device
is normally the only line of protection from overloads and
high impedance faults when using instantaneous-trip circuit
breakers. A failure of the overload device, the overload wiring,
or the contactor can prevent the circuit from being isolated due
to overload or high-impedance fault conditions. Where backup
protection is desired for these abnormal conditions, an inverse-
time circuit breaker or fuses should be selected. Fig. 6 shows
a thermal-magnetic breaker with a 100-hp motor to illustrate
the backup protection provided in the overload region.
E. Energy Efficient Motors
To comply with the Energy Policy Act of 1992, certain
motors manufactured after October 24, 1997 must meet new
efficiency standards. Design E motors comply with these
standards. However, the most commonly available motors to
meet these standards are energy-efficient Design B motors.
The 1996 NEC permits especially high circuit breaker settings
for the Design E motors, and the 1999 NEC is considering
higher circuit breaker settings for energy-efficient Design B
703
Fig. 6. Backup protection using a thermal-magnetic MCCB.
motors. Energy-efficient motors are among those with which
low power factor, high starting currents can be expected. In
many cases, starting current for the Design B energy-efficient
motors will exceed the maximum permissible setting of 1300%
of FLC permitted by the NEC. In these cases, an instantaneous-
trip circuit breaker will not be suitable, and an inverse-time
circuit breaker, a fuse, or reduced voltage starting may be a
solution.
VIII. CONCLUSIONS
1) A “Listed” combination starter meets the requirements
of the NEC and is tested such that the combination of
components protects the motor and is self protecting as
a system. A system designer selecting components must
be aware of NEC requirements, as well as being aware
of the meaning of the ratings of the combination and its
components.
2) The combination starter must have a short-circuit current
rating adequate for the available short-circuit current on
its supply side.
3) False tripping of instantaneous-trip circuit breakers is
an occasional problem when motors are starting. The
asymmetrical starting current causes the breaker to trip
without a fault condition. In some cases, the maximum
setting permitted by the NEC is not high enough to
allow the starting current to flow without tripping the
instantaneous-trip circuit breaker. Inverse-time circuit
breakers (thermal-magnetic or electronic-trip), fuses, or
reduced voltage starters may be required to satisfy NEC
requirements.
4) Coordination plots that simply show a straight line
for an instantaneous-trip breaker should be modified
to include the manufacturing tolerance around the set
point, as given in Table I. To avoid false tripping,
the asymmetrical starting current should be below the
minimum Table I tolerances of the set point.
704 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 34, NO. 4, JULY/AUGUST 1998
5) The contactor should be tested to break high-impedance
fault conditions it may see and to withstand the motor’s
LRC. Any condition at or below the maximum Table
I tolerances of the set point of the breaker should be
within the tested break value of the contactor. Magnetic
or vacuum contactors that have adequate break values
may be applied to avoid welding of contacts.
ACKNOWLEDGMENT
This paper was the result of considerable work and dis-
cussion by members of the Molded-Case Circuit Breaker
Applications Working Group of the IEEE Industry Appli-
cations Society Power Systems Protection Committee. The
authors thank J. Andrews, B. Bailey, R. Clark, K. Cooper,
J. Fischer, W. Hall, G. Irvine, D. Love, Don McCullough,
Alan Pierce, Vince Saporita, and Ray Valentine, members of
the Working Group, for their contributions to this paper as
well as to nonworking group members who provided support.
REFERENCES
[1] Industrial Control Equipment, ANSI/UL Standard 508-1993.
[2] ANSI/NFPA 70, 1996 National Electrical Code, National Fire Protection
Association, Quincy, MA, 1996.
[3] Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-
Breaker Enclosures, ANSI/UL Standard 489-1996.
[4] Industrial Control and Systems Controllers, Contactors, and Overload
Relays Rated Not More Than 2000 Volts AC or 750 Volts DC, NEMA
Standard ICS-2-1993.
[5] L. K. Padden and P. Pillai, “A flow chart methodology for performing
low-voltage three-phase motor coordination studies,” in Conf. Rec. IEEE
PCIC Conf., 1997, pp. 11–23.
[6] R. R. Burke and W. R. Finley, “Trouble shooting motor problems,” in
Conf. Rec. IEEE PCIC Conf., 1993, pp. 303–316.
[7] R. L. Nailen, “Motor inrush current: What does it really mean?,” Elect.
App. Mag., pp. 56–60, June 1986.
[8] H. L. Bradfield and D. W. Heath, “Short-circuit protection of energy
efficient motors,” IEEE Ind. Applicat. Mag., vol. 3, pp. 41–44, Jan./Feb.
1997.
George D. Gregory (S’69–M’70–SM’97) earned
the B.S.E.E. and M.S.E.E. degrees from the Illinois
Institute of Technology, Chicago.
He is presently Manager, Industry Standards,
Square D Company, Cedar Rapids, IA. Since joining
Square D Company in 1985, he has held a variety
of positions, including Chief Engineer, and Product
Manager for Molded-Case Circuit Breakers. Prior
to 1985, he served as Design Manager for Circuit
Breakers with GTE Products, Puerto Rico, and
as Engineering Group Leader with Underwriters
Laboratories, Chicago, IL. He is currently Chair of the NEMA Circuit Breaker
Section, Deputy Technical Advisor to the IEC 17B Subcommittee, and a
member of National Electrical Code Panel 10 (representing NEMA).
Mr. Gregory is Vice Chair of the IEEE Industry Applications Society Power
Systems Protection Committee, Chair of the Blue Book Working Group, a
Chapter Chairman in the Buff Book Working Group, and a contributor to the
Battery Systems Protection Working Group. He is a Registered Professional
Engineer in Illinois, Iowa, and Puerto Rico.
Lorraine K. Padden (S’81–M’83–SM’94) received
the B.S. degree in electrical engineering in 1983
from the South Dakota School of Mines and Tech-
nology, Rapid City.
Following graduation, she was with Shell Oil
Company and subsidiaries in Houston, TX, and Bak-
ersfield, CA. As a Facilities Engineer, she designed
and managed production facilities projects from
conception to completion. In 1992, she founded
Padden Engineering, LLC, Katy, TX, a consulting
company, of which she is President. She has been
providing electrical engineering services to the petrochemical industry since
1983, specializing in power system design and analysis and coordination
studies, including plants up to 700 MW.
Ms. Padden is a member of the IEEE Industry Applications (IAS) and
IEEE Power Engineering Societies and has served on several committees,
including a term as Chair of the IAS Petroleum and Chemical Industry
Committee Production Subcommittee. She is also a member of the American
Petroleum Institute, National Fire Protection Association, Society of Petroleum
Engineers, International Society for Measurement and Control, and National
Society of Professional Engineers, and an affiliate member of the International
Electrical Testing Association. She is a Licensed Professional Engineer in the
States of Texas, California, and Washington.