Sizing The DOL Motor Starter Parts (Contactor, Fuse, Circuit Breaker and Thermal Overload Relay)

Calculate size of each part of DOL motor 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 and overload relay of starter is put before motor. Basic Calculation of Motor Torque and Current Motor Rated Torque (Full Load Torque) = 5252xHPxRPM Motor Rated Torque (Full Load Torque) = 5252x5x750 = 35 lb-ft. Motor Rated Torque (Full Load Torque) = 9500xKWxRPM Motor Rated Torque (Full Load Torque) = 9500x(5×0.746)x750 = 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 Overload Relay Thermal Overload Relay (Phase): Min. Thermal Overload Relay setting = 70%x Full Load Current(Phase) Min. Thermal Overload Relay setting = 70%x4 = 3 Amp Max. Thermal Overload Relay setting = 120%x Full Load Current(Phase) Max. Thermal Overload Relay setting = 120%x4 = 4 Amp Thermal Overload Relay (Phase): Thermal Overload Relay setting = 100% x Full Load Current (Line). Thermal Overload 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 Compressor Motor with Auto O/L Reset AC8b 6 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.