Motor Control:Reasons for Overload Protection

Reasons for Overload Protection

As stated earlier, excess current flowing through a motor winding will cause overheating. This in turn will result in damage to the winding insulation. If this occurs the motor is described as being “burned out” and must be rewound or replaced.

Here are some of the reasons why motors burn out:

No overload protection Incorrect overload relay fitted Incorrect overload relay setting The main functions of thermal type overload relays are to prevent burn out of windings due to overloading or single phasing. Overloading applies to all motors, while single phasing only applies to three phase motors. See below.

Overloading

When the load is increased on an induction motor the rotor speed reduces and the current taken by the motor increases. When this current rises above the motor Full Load Current, the motor is considered to be overloaded. Generally speaking, motors can cater for a 110 – 120% overload. Consequently overload devices are calibrated to allow for this. An overload relay set at 10 Amps will trip after a time delay, on a load current of 10 + 15% = 11.5 Amps.

A thermal overload relay will allow for the starting current of an induction motor. It takes time to heat the bi-metal strips. This provides a time lag to allow the starting current flow for a sufficient period of time to get the motor up to full speed.

Low value overloads will be detected and acted upon after a period of time.

Higher value overloads will be detected and acted upon in a shorter time.

Single Phasing

If a break occurs in any one phase of the supply to a three-phase induction motor, the motor will continue to run on two phases depending on the load. If fully loaded it will probably stall and must be quickly disconnected from the supply as the load current will rise sharply. If it is not fully loaded it will continue to operate the load. In order to do so it will slow down and draw more current from the remaining two phases. This condition is called “single phasing”.

A bad connection, a blown fuse or a faulty contactor main contact will produce this effect.

A motor will generally not start on two phases; if it does start it will do so very slowly.

This is undesirable and will cause damage to the motor winding(s). Most thermal overload relays are equipped with a differential device. This simply means that they can differentiate between all three bi-metals being heated and only two being heated. If only two bi-metals are heated the relay will operate at a lower load current. In this way it provides protection against damage due to single phasing.

Note This is the reason why all three heater elements must be used on a single phase motor circuit.

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