Protection

SIPROTEC
Thermal Motor Protection

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Agenda

General introduction thermal model

Thermal model in detail
Stator overload
Motor starting time supervision
Thermal rotor model for restart inhibit function
Thermal rotor model for negative sequence consideration
General setting recommendations

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Thermal modeling of a motor?

Ambient
Thermal model becomes
C,2 C,1 Rth,1
very complicate Simplification is necessary
Hous-
ing
Differential equation higher
order One body model
Rth,2
C,4
Parameters are not given by
Rth,4
Fe losses Fe Rotor the motor manufacturer (description via differential
equation first order)
Rth,3
Rotor losses Rth thermal resistance
Cu Cu losses
C thermal capacitance
C,3

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Siemens approach

Consideration of thermal behavior in different functions

Running motor
Thermal model for stator (load current)
Thermal model for the rotor or definite time stages (I2 current)

Start or restart of the motor

Starting time supervision (I2 t curve)
Thermal model of motor (rotor) restarting (IStarting current)

General
Temperature supervision via RTD sensors

Note: Different motor protection suppliers have different approaches (main reason: technical history)

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Discussion of the realization in detail

Thermal Overheating of the Stator

during continuous operation

Thermal Overheating of the Rotor

during start (too long, locked rotor)
during too frequent starts
during a negative sequence current
loss of phase
unsymmetrical voltage

Thermal overheating of bearings

Thermal overheating of plant on unloaded drives

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Stator Overload
Thermal overload impact (general)

Ppl = Relc I2 Ppl: power loss (active power), Relc: electrical resistance, I: current

PCV

Ppl

Temperature rise if Ploss > PConvection Overheating

High temperatures lead to a stress of insulating material and reduces the
lifetime / loss insulating ability (breakdown caused by temperature )
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Thermal modeling

d( 0 ) - (a - 0 ) d
I 2 = C th + I 2 R th = R th C th + - (a - 0 )
dt R th dt
Assumption I2max * Rth leads to max

d
I 2p.u. = th+ - a
dt
with the following scaling
I I a - 0 a - 0
I p.u. = = = = 2 th = R th C th U = = 2
I max k I N,M max k N max k N
Actual motor temperature
0 Reference temperature ( 40C) Solution of (
(t) = I 2
p.u. + a t =0 ) t

1 e th + t =0
a Ambient temperature
differential equation

2

2

1 I I
1 preload
2 IN,M rated motor current (NEMA: FLA)
2
k I N,M k I N, M N temperature at rated current

Calculation of the trip time ((t) =1) t = th ln k factor describes the maximum
1 I 1 a,measured 0
2 permissible load current (k =1.1)

2 + 2 1 th thermal time constant

k I N,M k N
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Temperature rise after load current increasing
(Ipreload = 0)

(t), (I/IN,M)2

(I/k I N,M ) 2 Thermal

t = th ln memory
(I/k I N,M ) 2 1
100% tripping threshold
k2
IN,M rated motor current excess temperature (t)
(full load current, FLA)
k permissible overload factor

th thermal time constant

tTrip
th t

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 Stator Overload
Influence of the ambient temperature

Model: I2

Influence of ambient temperature on reference temperature:
C R U ref = Environment 40C = RTD 40C

ref

(t), (I/IN,M)2

Environment < 40C

100% Tripping
k2 Shift of
Temperature tripping threshold

Environment > 40C

tA th t

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Page 9 January 2015 Energy Automation Products
Stator Overload
Tripping time at different overload conditions

Relation between e-function and tripping characteristic

22 = 4 N
( I )2
IN

1,52 = 2,25 N
Calculation:
100% 1,12 (1,21)
tripping threshold x% 12 (1)

1,12 = 1,21 N = tripping temperature A (100%)

1 = N = 0,83 A (83%) x = 83%

= N (1 - e -t/T) At the rated current the thermal

memory has reached a level of
I t
IN
tripping characteristic ttrip = f (I/ Imax)
2 (k = 1,1) Tripping characteristic is always inverse
1,5
1,1
1

ttrip

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 Stator Overload
Behaviour of thermal model with preload

100% Preload := Motor Nominal Current (FLA)

I2

tripping threshold
(K N)2
100%

1 I 2 1 I
2


80%
preload

k I N,M k I N, M
2 2

60% t = th ln

2
1 I

k 2
I 1
N,M

ttrip1 ttrip2 ttrip3

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Stator Overload
Estimation of the thermal memory level

Solution of the differential equation was: (t) = I ( 2

p.u. + a t =0 ) t

1 e th + t =0

2

Stationary conditions after 5 : 1 I 1 a 40C

(t = 5 th ) = I p.u. + a = 2
2
+
k I N,M k 2 N
1 I 2 1 40C
Thermal Memory [%] = 2 + 2 a 100%
k I k N
N, M

Examples: k= 1,1; N = 100C

Case 1: I = IN,M and a = 40C Case 2: I = IN,M and a = 55C

1 I N.M
2
1 2

I N,M
Thermal Memory [%] = 2
I
100% = 82,6 %
Thermal Memory [%] = 2 + 1 2 55C 40C 100% = 95%
1,1 1.1 I 1.1 100C
N,M N,M

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Special countermeasures avoid over and under function

Using of true RMS currents (consideration of harmonics)

Evaluation of phase segregated currents (consideration of unsymmetrical load currents)
Tripping at maximum phase current (Trip := Max (L1, L2, L3))
Control of thermal model during motor start (avoid overfunction in hot motor status)1)
Strategy 1: Freeze of thermal model during motor start
Strategy 2: Limit the input current (< 2.5 IN,M) Consideration of stator winding heating
Control of thermal time constant at different load conditions
Different load current at a running motor: cooling down and heat up time constant are equal
During shut down or after trip: set cooling down time is used (e.g. no cooling via fan)
(If no value given cooling := (5-7) * heating is a good approach)

Note:1) Use strategy 1 at motors with very long starting time (e.g.. 50 s) to avoid a trip at hot starting condition.

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Stator Overload
Tripping time at different conditions

Parameters:
k =1,1
Ipreload = IN,M (full load current (FLA))
th = 900 s (15 min)

N = 100C
a = 55C

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Thermal Overload Rotor
Faults during start

Mechanical causes
Locked rotor (n = 0)
Inhibited start due damage or destruction of motor or drive
components or insufficient unloading of the driven machine
(accelerating torque too small) tst > tst,normal
Failure to unload the drive on the process side;
load torque > motor torque (0 < n < nN; tst > tst,normal)

Electrical causes
Interruption of a phase (n = 0)
Undervoltage (tst > tst,normal)

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Thermal Overload Rotor
Starting time supervision

I
1 Current during locked rotor
U = UN 1
IStart
(Motor data) 2 Current during start up of motor
2

U < UN 2
IStart
t = t Start
I
Threshold of motor start up
IStrt>
(Setting)

IOperation = IM

tStart t
(Motor data)

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Thermal Overload Rotor
Starting time measurement in a test lab

8
8

6
Multiple of rated motor current

I1 k
j

I2 k
j 4

IKL
j

0.77 0
0 2 4 6 8 10 12 14
0.1 t1 , t2 , tKL 13.5
j j j
Time in seconds
Starting current at U = Un
Starting current at U = 0,85 Un
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Thermal Overload Rotor
Lock rotor or stall time < acceleration time

I
1 Current during locked rotor
U = UN 1
2 Current during start up of motor
IStart
(Motordata)
2 Trip at:
I>Istrt> &
t>tLocked rotor &
n < nLimit

Threshold of motor start up

IStrt>
(Setting)
Limit of
locked rotor
IOperation = IM time

tLocked rotor tStart t

(Motor data)

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Thermal Overload Rotor
Too frequent motor starts

Thermal stress of the rotor

Overheating of the rotor
Reduction of motor life time

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Thermal Overload Rotor - Too frequent motor starts
Thermal model approach

1. Typical data of a motor

- Number of warm starts nW
- Number of cold starts nC
- Starting time tSt
- Starting current ISt
2. A thermal model 1. order is sufficient (exponential-function)
- C St
n t
3. Equations cold I : (k R I B ) = I St2 1 - e R
2


n t

( )
- w St
warm II : (k R I B ) = I St2 I B2 1 - e R + I2
2
B

4. Solutions: nC (1)
kR
nC - n W
2
St
Note: R t St (nC - n W ) (2)
IB = IN,Motor B
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Thermal Overload Rotor - Too frequent motor starts
Temperature characteristic during repeated start
MAX
100% 400

therm.
model

Threshold of restart inhibit

K
TA

K = temperature curve at rotor cage bar upper site limit

TA = thermal model

Krun Kstop
Minimum restart inhibit time tinhibit
start up recovery start up recovery start up

0% 40

t
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Thermal Overload Rotor - Too frequent motor starts
Thermal memory at different start conditions

Given settings:
Thermal limit of the rotor nc = 3; nw = 2
kR = 1,73
Ist = 6 IN,M
R = 355 s
tst =10 s

Threshold of Restart inhibit

(0,67)
Restart inhibit
is active Actual rotor
temperature

Starting current
10 s 7,5 s 5s

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Thermal Overload Rotor
Loss of phase or unsymmetrical voltage

Thermal stress of the rotor

Overheating of the rotor due to negative sequence current
Reduction of motor life time

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Thermal Overload Rotor
Influence of unsymmetrical voltage

UA

UA Positive
Sequence
UC UB

UA
UB Negative
UC UB UC Sequence

Due to the low negative sequence reactance a negative voltage

sequence leads to a high negative sequence current

1 % of U2 (5 - 6) % of I2

A thermal negative sequence model has advantages

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Thermal Overload Rotor - Loss of phase or unsymmetrical voltage
Realization of protection function

The protection function calculates the negative sequence current I2 from the 3 phase currents

For evaluation of I2 there are two approaches

Definite time stages Thermal model according (I2/IN,M)2 t = K

(given a synchronous motors)
t t

Alarm
(10 30) s (10) s

Thermal characteristic
(I2/IN,M)2 t = K (2 5s)

(5 2) s

10% 15%-40% I2/IN,M

I2 perm. I2/IN,M
app. 10%

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Thermal Protection via RTD elements
(stator winding, bearing temperature supervision)

Cooling unit Stator winding

(2 x RTDs) (6 x RTDs)

Bearing temperature Hot-air temperature Cold-air temperature Bearing temperature

(2 x PT100) (1 x PT100) (1 x PT100) (2 x PT100)

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Insulation Design of Stator Winding
Design according temperature classes

Thermal class Maximum permissible Maximum temperature

(insulation class) continuous temperature according EN61558

A 105 C 100 C Most motors are designed

according class F and operation
E 120 C 115 C
is according class B
B 130C 120 C Data sheet: F/B
F 155 C 140C
H 180 C 165C

Practical approach: Bearing temperature trip:

Recommendation:
Measure temperature at Journal bearing: 95 C
Trip level of RTD sensor is 155 C rated load Load C Rolling-contact bearing: 110-115 C
Alarm level of RTD sensor is 140 C Alarm: Load C + 10 K
Trip : Load C + 15 K

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Setting of thermal protection functions
Possible technical data (data for the stator overload)

Maximum permissible current: k =1.15 (or calculated from

maximum permissible current)
Note:
If Temperature class F/B is given then k =1.1 is always
possible
NEMA service factor (power rating in allowed V (10%) and f range)
SF=1.0 k = 1.1 (0,9 Ur *1.1 Ir 1 Ur Ir
SF= 1.15 k = 1.25 (conservative: 1.15)

Thermal time constant: 25 min

Cooling time constant: 175 min
Note: The diagram shows the thermal curve from the
copper winding (its only relevant for short-time duty)
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Setting of thermal protection functions
Possible technical data (data for the starting time supervision

The technical data gives the following values:

Design of the starting time supervision between limits:

Motor starting: 5,65 I/IN and locked rotor time (hot) 9s
Setting recommendation:
IStart = 5,65 I/IN,M; Istr> = 2,5 I/IN,M
tStart = 7.5s
2
5.6
At: I = 3,9 I/IN,M t = 7,5s = 15,5 s
3.9
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Setting of thermal protection functions
Tripping curve for the discussed example

Stator overload
th = 25 min
k = 1.1
Current limit: 2,5 I/IN,M

Starting time curve

Istart = 5,65 I/IN,M
Tstart = 7.5 s
Release current: 2,5 I/IN,M

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Setting of thermal protection functions
Given overload curve (Example 2)

Calculation of the thermal parameters

Select a value for k (e.g. k = 1.1)
Take a current (e.g. 1,5 I/IN,M) and read out the time from
200 s
the given curve
Calculate the time constant
1
1 I 2 1 I 2

preload

k 2 I N,M k 2 I N, M
th = ln * t(I
selected )

2

1 I

k 2
I 1
N,M
Given: S.F selected k =1,1
At 200% FLA 200s (curve at lower is shown in detail)
Assumption: cold Ipreload = 0
th = 9,2 min

Compared with the previous calculation, it shows that the copper time constant
is given in the thermal limit curve. There is a risk, that during motor starting a trip at
hot condition occurs; selected thermal time constant: 20 min (S1 duty assumed)
(current limitation: 300 %FLA)

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Setting of thermal protection functions
Tripping time curve (Example 2)

th = 9,2 min th = 20 min

k = 1.1 k = 1.1

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Setting of thermal protection functions
Tripping curve for the discussed example 2

Stator overload
th = 20 min
k = 1.1
Current limit: 3 I/IN,M

Starting time curve

Istart = 5,6 I/IN,M
Tstart = 8 s
Release current: 3 I/IN,M

Starting values from the given starting curve:

500% FLA 7s at 100% voltage
400% FLA 10s at 80% voltage
360% FLA 12 s at 80% voltage

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Setting of thermal protection functions
Restart inhibit function

Longest starting time is at lowest allowed voltage

Setting parameters:
Cold starts: 3
Warm starts: 2
3 cold starts
Starting current: 3,9 I/IN,M
Starting time: 10s
Than the motor
Restart inhibit
operates with the threshold
Internal calculated
load current
(95%)
nC 3
kR = = 1,73
nC - n W 3-2
2

R t St (nC - n W ) St = 10s *1 * 3,9 2 = 152s
B

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Setting of thermal protection functions
Unbalanced load protection (negative sequence protection)

Data are available for synchronous motor Data for asynchronous motors are missing in the most cases

Setting strategy:
Follow the general setting recommendation from slide before
(it is a conservative setting strategy)
Follow the setting recommendation from vendors manual
Ask the motor manufacturer for more detailed setting values
Results from a test in the Lab:
5% U2/U1 (app. 25%I2) Motor operation 130min Winding temperature increased by12 K

50 %U2/U1 (app. 150%I2) Motor operation 60 sec Winding temperature increased by120 K

t t

20 s Alarm
(10) s
I2, perm.= 8% Thermal characteristic
(I2)2 t = 20s Alarm (I2/IN,M)2 t = 2 s
only
8s
10 s
20 s 8s
2s
1I2
3s
I2 perm. 50% 100% I2/IN,M
app. 10%
10% 25% 40%
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Motor Protection

Dr. Hans-Joachim Herrmann

Principal Key Expert Protection
(Product Management)
EM DG PRO LM PR
Humboldt Street 59
91459 Nuremberg
Phone: +49 (911) 433 8266
Fax: +49 (911) 433 8301
Mobile: +49 (172) 3265902
E-mail:
hans-joachim.herrmann@siemens.com

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