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Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is notalready in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Chapter : Electrical For additional information on this subject, contact
File Reference: EEX21606 W.A. Roussel on 874-1320
Engineering EncyclopediaSaudi Aramco DeskTop Standards
Motor Starter Components And Standards
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CONTENTS PAGE
MAJOR COMPONENTS OF AC MOTOR STARTERS......................................1
Overload Protection....................................................................................3
Controller....................................................................................................5
Fault Protection ..........................................................................................7
Disconnect..................................................................................................9
Enclosure..................................................................................................10
MOTOR STARTER STANDARDS....................................................................11
Industry Standards....................................................................................11
NEC Article 430 ...........................................................................11
ANSI/IEEE Standards...................................................................13
NEMA Standards..........................................................................14
Saudi Aramco Standards ..........................................................................14
SAES-P-113 Motors and Generators ............................................14
SAES-P-114, Chapter 6, Motor Protection...................................14
16-SAMSS-503 Low Voltage Motor Control Centers and
Switchracks (600 V and Below) ...................................................1416-SAMSS-506 Medium Voltage Motor Control Center .............14
Drawing 990-P-AB036766...........................................................15
GLOSSARY ........................................................................................................17
LIST OF FIGURES
Figure 1. Major Functional Components of a Motor Starter................................2
Figure 2. Typical Three-Pole Thermal Overload Relay.......................................4
Figure 3. Contact Arrangement for One Pole of a Typical
Controller..............................................................................................5
Figure 4. Typical Three-Pole Magnetic Contactor...............................................6
Figure 5. NEC Article 430 .................................................................................12
Figure 6. Commonly Used Symbols for One-Line Diagrams............................16
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MAJOR COMPONENTS OF AC MOTO R STARTERS
Alternating current (AC) motor starters have five major functional components as illustrated
in the diagram shown in Figure 1. These include:
components that provide motor overload protection.
components that perform the motor controller function.
components that protect against short-circuit and ground faults.
components that provide motor circuit disconnecting means.
an enclosure suitable to meet the requirements of the motor starter application.
These components and their functions are described in the following sections.
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Figure 1. Maj or Functional Components of a Motor Star ter
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Overload P r otection
One of the most important components common to all motor starters is the device used to
provide running overload protection for the motor, its control circuits, and the connecting
circuit conductors. Selection and sizing of this device is guided by specific requirementsgiven in the National Electric Code for motor running overcurrent (overload protection).
The definition of running overcurrent (overload) is the operating overcurrent up to and
including stalled-rotor (locked-rotor) current. Overcurrent, however, does not include fault
currents due to shorts or grounds. When overcurrent persists for a sufficient length of time, it
causes overheating and possible damage to the motor and its circuit components.
The function of the overload device is to monitor motor line current and to open the motor
circuit when predetermined safe levels are exceeded. In accordance with the National Electric
Code and based on specific circuit conditions, continuous duty motors rated more than one
horsepower may be protected for overloads using overload relays, integral thermal protectors,
fuses or circuit breakers. The most commonly used overload device is the overload relay.
Two types of overload relays that respond to the heating effect of the motor line current are
the thermal and the solid-state overload relays. The thermal overload relay uses the motor
line current to produce heat within itself at a designated rate that simulates load and conductor
heating. On the other hand, the solid-state overload relay monitors motor line current and
uses semiconductor circuits to determine the heating effects that the level of current will have
on the motor and conductors. The motor starter in Figure 1 shows an example of a thermal
overload relay being used for the overload protection. Figure 2 shows a typical three-pole
thermal overload relay.
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Figure 2. Typical Thr ee-Pole Therm al Overload Relay
All thermal overload relays have an operating memory. Operating memory means that the
relays respond as if they remember that the load they are protecting has been operating at
some rate, and that it may not be cold when returned to service after an overload. Some types
of solid-state overload relays have an equivalent operating memory to keep track of the
accumulated overload duty. This equivalent operating function can be provided in various
ways, such as by charging a capacitor or by altering the count in a register of a
microprocessor.
As illustrated in Figure 1, overload relays are connected on the loadside of the magnetic
contactor. Each relay has two major parts. There is the thermal sensing element, often
referred to as the heater, and there are the overload relay contacts. The thermal sensing
element is directly acted on by the line current drawn by the motor. If the motor load current
exceeds the rated value of the thermal element for a specified length of time, the relay reacts
to open the overload contacts, which in turn breaks the control circuit to the starter coil, thus
shutting down the motor. The time-current response characteristics of the overload relay
ensure that the motor is automatically shut down before an overload can persist to the point
where the motor becomes overheated and damaged.
Specific types of overload relays (e.g. bi-metallic, solder-pot and solid-state) and the methods
used to select them are described in Module EEX 216.04.
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Controller
A major component common to all AC motor starters is the controller. The controller consists
of the contactor that carries the motor line current and the control circuit for the contactor.
When the overload relays (described in the preceding section) are added to the controller, theassembly is referred to as a basic magnetic motor starter.
The contactor portion of the controller is essentially an on-off device operated by
electromagnetic means. When the controller coil is energized through a control circuit, the
resulting magnetic field mechanically forces the main contacts to close, thus starting the
motor. The coil is then continuously energized to hold the contacts closed and keep the motor
running. When the coil is deenergized, the main controller contacts are forced open by either
spring pressure or gravity, thus stopping the motor. Figure 3 illustrates the arrangement of the
current carrying contacts, coil, and moving armature for one pole of a contactor. Contactors
are typically designed in two-, three-, four-, and five-pole configurations. Note in Figure 3
that the flow of power for the contact arrangement is in a straight line, into the line side of theassembly and out of the load side. This feature, common in most controllers, is referred to as
straight-through wiring. Figure 1 illustrates a controller that uses a three-pole contactor to
make up the full-voltage, non-reversing AC motor starter. A typical three-pole magnetic
contactor is depicted in Figure 4.
Figur e 3. Contact Ar rangement for One Pole of a Typical Contr oller
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Figur e 4. Typical Thr ee-Pole Magnetic Conta ctor
The contactor portion of the controller must be able to continuously carry the full-load current
and to safely interrupt the locked-rotor current of the motor being controlled. If the motor
stalls, or if it does not start properly (it is jammed and cannot begin to turn), the current drawn
by the motor is referred to as the locked-rotor current. This current is typically 400-600% of
the full-load current of the motor (the same as the starting current), and the contactor must be
capable of safely opening the circuit under this condition.
Because both the full-load and locked-rotor currents are a function of the horsepower rating at
a specified voltage, motor controllers are rated for the maximum horsepower they can safely
handle at these voltages. Horsepower ratings for low voltage controllers (NEMA sizes 00
through 9) and medium voltage controllers (NEMA sizes H2 through H6) are listed in NEMA
Standard ICS-2. Saudi Aramco Standard SAES-P-114 requires that motor controllers be
applied in accordance with their horsepower rating.
Horsepower ratings and NEMA standard sizes for controllers are described in Module EEX
216.04.
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Fault Pr otection
Another of the major components that is common to all AC motor starters is the device used
to provide protection against short circuit and ground faults.
The devices used for this protection are typically an instantaneous trip circuit breaker, an
inverse time circuit breaker, nontime delay fuses, or dual element (time-delay) fuses. The
example motor starter illustrated in Figure 1 shows that either nontime delay fuses or an
inverse circuit breaker can be used for the short-circuit and ground fault protection.
Saudi Aramco standards require that only circuit breakers be used for the fault protection
function. The one exception to this requirement is for cases where combination Class E2
starters with current limiting fuses, may be used for induction motors 4000 volts or greater
and 1500 horsepower or less. When circuit breakers are used, they serve as two components
for the motor starter. First, they serve as the fault protection device, and second, they serve as
the disconnecting device.
The fault protection device must provide protection for the complete motor branch circuit,
which includes the circuit conductors, the control apparatus and the motor.
To provide for safe and effective sizing of the fault protection device, the National Electric
Code defines requirements and maximum ratings to be used. The first requirement for the
fault protection device is that it be capable of carrying the starting current of the motor
without opening the circuit. The next requirement is that the rating or setting of the device
not exceed maximum values given in the National Electric Code. Sizes, ratings and functions
of fault protection devices are described in detail in Module EEX 216.04.
As mentioned above, the device used for fault protection may be a type of fuse or circuitbreaker, depending on the application and circuit requirements. The following paragraphs
briefly describe the characteristics for some of these devices. Low voltage fuses (600 volts or
less) come in two basic shapes: the plug fuse and the cartridge fuse. They may be current
limiting or non-current limiting. Cartridge fuses are either renewable or nonrenewable.
Nonrenewable cartridge fuses are assembled at the factory, and are replaced after they open in
service. Renewable cartridge fuses can be disassembled, and the fusible element can be
replaced. A special type of low voltage fuse that is sometimes used is the dual-element or
time-delay fuse. The dual-element fuse has one element that is fast-acting and responds to
overcurrents in the short-circuit range, while its other element permits short-duration
overloads, but melts if the overload is sustained.
Medium voltage fuses (over 600 volts) are called power fuses. Power fuses are either current
limiting or non-current limiting. A non-current limiting power fuse is more commonly called
an expulsion fuse. Current limiting fuses are categorized as either general purpose (E-rated)
or R-rated. R-rated current limiting fuses are specifically used for fault protection, in Class
E2 controllers, for medium voltage motor short circuit protection.
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Molded-case circuit breakers are a class of breaker rated at 600 volts and below. These
breakers consist of a switching device and an automatic protective device assembled in anintegral housing of insulated material. These breakers are capable of clearing a fault more
rapidly than a low voltage power breaker. Solid-state trip units incorporated into some styles
of molded-case breakers provide for their coordination with power breakers. Molded-case
breakers are generally sealed to prevent tampering, which in turn precludes any inspection of
the contacts. They are generally not designed to be maintained in the field, and manufacturers
recommend total replacement if a defect appears.
Molded-case circuit breakers are available in several different types. The thermal magnetic
type, the most widely used, employs thermal tripping for overloads and magnetic tripping for
short-circuits. The magnetic type employs only instantaneous magnetic tripping for cases
where only short-circuit interruption is required. The integrally fused type combines regularthermal magnetic protection together with current limiting fuses to respond to applications
where higher short-circuit currents are available. In addition, the current limiting type offers
high interrupting capacity protection while at the same time limiting the let-through current to
a significantly lower value than is usual for conventional molded-case breakers.
The motor circuit protector (MCP) is a specific class of molded-case circuit breaker having a
special adjustable instantaneous trip circuit designed primarily for motor short-circuit
protection. Major features of the MCP are that it can respond to the occurrence of low level
faults in motor windings and typically clear them faster (less than one cycle) than a fusible
device. SAES-P-114 permits MCP use for low voltage motor protection greater than 1 to 100
horsepower.
Low-voltage power circuit breakers (LVPCB), like molded-case breakers, are rated 600 volts
and below. They differ, however, because they are typically open-construction assemblies on
metal frames with all parts designed for accessible maintenance, repair, and ease of
replacement. They are intended for service in switchgear compartments or in other enclosures
of dead front construction. Tripping units are field adjustable, and include electromagnetic,
direct acting, and solid-state types. They can be used with integral current-limiting fuses to
meet interrupting requirements up to 200 kA RMS symmetrical. SAES-P-114 requires the
use of LVPCBs for low voltage motor fault protection greater than 100 horsepower.
Medium-voltage power circuit breakers (MVPCB) are primarily circuit opening and closingdevices for use on circuits with distribution voltages up to 15 kV. Unlike low-voltage
breakers, they do not incorporate built-in automatic trip units. Separate protective relays are
used to monitor the circuit conditions and then to send an electrical signal to trip the breaker.
MVPCBs are available in a wide variety of designs, primarily identified by their interrupting
medium: air, air blast, vacuum, or gas (SF6). MVPCBs are basically an enlargement of the
low-voltage power circuit breaker with larger insulators and interrupting assembles to handle
the higher voltages and larger interrupting currents. SAES-P-114 requires the use of
MVPCBs for medium-voltage motor fault protection greater than 1500 horsepower.
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Disconnect
Another major component that is common to all AC motor starters is the disconnecting
device. In accordance with the National Electric Code, motors and controllers must be
provided with a means of safely disconnecting them from their source of supply so thatmaintenance of the controller, motor, and its driven equipment can be accomplished with no
hazard to personnel.
The devices permitted by the NEC to be used for disconnecting include circuit breakers,
motor-circuit switches, and molded case switches (nonautomatic circuit interrupters). For
purposes of definitions, a motor-circuit switch is a horsepower-rated switch capable of
interrupting the maximum overload current of a motor. A molded case switch (nonautomatic
circuit interrupter) is a circuit breaker-like device without the overcurrent element and
automatic trip mechanism. It is rated in amperes and is suitable for use as a motor circuit
disconnect based on its ampere rating.
The disconnect, additionally, must open all the ungrounded supply conductors and be gang-
operated so that the one operating mechanism opens all poles simultaneously. The device
must give a clear indication of its status, open or closed, be rated in horsepower, and be
capable of interrupting the locked-rotor current of a motor of the same horsepower rating.
The horsepower rating is required in the event that a motor stalls, and the motor controller
fails to properly open the circuit. When the disconnect switch is operated, it must interrupt
the locked-rotor current of the motor, which is typically 400-600% of the motor full-load
current.
With regard to location, the disconnecting means must be located in sight from the controller,
the motor location, and the driven machinery location. For motors over 600 volts, thecontroller disconnecting means may be out of sight of the controller, provided the controller
has a warning label indicating the location and identification of the disconnecting means. In
addition, the disconnect must be capable of being locked in the open position.
The NEC requires that a switch, circuit breaker, or other device serve as a disconnecting
means for both the controller and the motor, thereby providing safety during maintenance and
inspection shutdown periods. The disconnecting means also disconnects the controller;
therefore, it cannot be a part of the controller. However, separate disconnects and controllers
may be mounted on the same panel or contained in the same enclosure. This type of
arrangement is referred to as a combination starter, and it is the most common arrangement
used in motor control centers.
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Enclosure
A final component common to AC motor starters is the enclosure. An enclosure is a
surrounding case constructed to provide a degree of protection to personnel against incidental
contact with the enclosed equipment, and to provide a degree of protection to the enclosedequipment against environmental conditions.
Although other types of materials (e.g. polymeric) are sometimes used, enclosures are
typically sheet metal or cast metal construction. However, in all cases, only material that will
not support combustion in air is selected for enclosures.
In many cases, the controller and the overload relay are contained in the same enclosure. For
some motor starters, the disconnecting means and/or the branch-circuit fault protective device
are also included in the enclosure with the controller and overload relays. When all of the
elements (devices) are in the same enclosure, the assembly is referred to as a combination
starter.
Enclosures are designated by a type number which indicates the environmental conditions for
which they are suitable. Applicable type numbers include Types 1, 2, 3, 3R, 3S, 4, 4X, 5, 6,
6P, 7, 8, 9, 10, 11, 12, and 13 as identified in NEMA Standard Publication No. 250. Types 7,
8, 9 and 10 enclosures are for use in hazardous (classified) locations. (Definitions for these
classifications are given in the National Electric Code, Article 500, and ANSI/NFPA 497M.)
NEMA enclosure types and classifications are described in Module EEX 216.04.
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MOTOR STARTER STANDARDS
An engineer should be familiar with the following Saudi Aramco and industry standards in
order to select low and medium voltage motor starters for AC induction motors.
National Electric Code (NEC)
American National Standards Institute/Institute of Electrical and Electronics
Engineers (ANSI/IEEE)
National Electrical Manufacturers Association (NEMA)
Saudi Aramco Engineering Standards (SAES)
Saudi Aramco Materials System Specification (SAMSS)
Industry Standards
NEC Art icle 430
The NEC is published by the National Fire Protection Association (NFPA). The intent of the
NEC is the practical safeguarding of persons and property from the hazards that can arise
from the use of electricity. The NEC is updated every three years through proposals that are
submitted by the public. The proposals must be reviewed and approved by a series of
committees and councils before the public proposal can become part of the standard. The
latest edition of the NEC is the 1993 edition (NFPA 70-1993). The NEC Article covers the
topics itemized in Figure 5.
Scope - NEC Article 430 covers motors, motor branch and feeder conductor circuits and theirprotection, motor overload protection, motor control circuits, motor controllers, and motor
control centers (MCCs).
Low Voltage Motor Articles - All of the Sections contained in Article 430, except for
Section J, pertain to low voltage motors.
Medium Voltage Motor Art icles - Section J Articles 430-121 through 430-127 recognize the
additional hazards associated with higher (medium) voltages.
Tables -Tables 430-150, 430-151 and 430-152 will be used throughout the entire course and
will be discussed in detail later.
NOTE: Although Article 430 covers motors, motor starters, etcetera, other articles in the
NEC, pertaining to motor circuits, cannot be ignored. For example, the number of
conductors in a raceway, and ampacity ratings of conductors are covered in other articles.
The fact that the conductors are for a motor circuit is irrelevant.
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Figure 5. NEC Art icle 430
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ANSI/IEEE Standards
ANSI/IEEE Standards provide information on how to design, test, measure, and specify
electrical systems and the preferred ratings of different pieces of electrical equipment. The
information in the ANSI/IEEE Standards represents the consensus opinion of a group ofsubject matter experts. The requirements and procedures that are given in ANSI/IEEE
Standards are useful in the design and application of motor starters.
C37.06-1987 Standard for Switchgear - AC High Voltage Circuit Breakers Rated on a
Symmetrical Current Basis - Preferred Ratings and Related Required Capabilities -
This standard lists the preferred ratings for medium voltage circuit breakers that are used in
Saudi Aramco installations for all motors above 5 kV as well as larger horsepower .600 to 5.0
kV motors.
C37.2-1991 Standard Electrical Power System Device Function Numbers - This standard
lists all of the device numbers and their functions. For example, ANSI Device 49 is a thermal
relay used to provide overload protection for a motor. Saudi Aramco requires all drawings,
diagrams, etc. to use the standard device numbers as listed in C37.2-1991.
C37.13-1990 Standard for Low Voltage AC Power Circuit Breakers Used in Enclosures
- This standard lists the ratings for low voltage power circuit breakers used in Saudi Aramco
installations for low voltage motors (under 600 V) and above 100 horsepower.
C37.46-1981 Standard Specifications for Power Fuses and Fuse Disconnecting Switches
- This standard lists the specifications for power fuses (NEMA Type R) used in medium
voltage 5 kV Class E2 motor starters, which are used in many of Saudi Aramcos
installations. Note: This standard was reaffirmed in 1987.
260-1978-Standard Letter Symbols for Units of Measurement - This standard lists the
letter symbols for all units of measurement; for example, mm for millimeter or f(x) for
function of x. Note: This standard was reaffirmed in 1991.
315-1975-Standard Graphic Symbols for Electrical and Electronics Diagrams - This
standard lists all of the graphic symbols for electrical and electronics diagrams. For the most
part, Saudi Aramco Drawing 990-P-AB036766 complies with 315-1975. Note: This
standard was reaffirmed in 1988.
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NEMA Standard s
ICS 1-General Standards for Industrial Control and Systems - This standard covers the
requirements for industrial control apparatus rated 750 volts or less DC, and 7.2 kV volts or
less AC. Of particular note is that this standard lists all definitions and graphic symbols forcontrol systems.
ICS 2-Industrial Control Devices, Controllers, and Assemblies - This standard covers
general purpose mechanical, electromechanical, and/or solid state (static) devices and controls
that are principally used in industrial applications for the control of motors.
MG-1-Motors and Generators - This is key industry standard governing the performance
and construction of motors and generators.
250-1991-Enclosures for Electrical Equipment (1000 Volts Maximum) - This standard
covers the classification and description of enclosures for electrical equipment. It is
considered the best source for determining specific applications of the numerous types of
enclosures.
Saudi Ara mco Standar ds
There are two types of Saudi Aramco standards pertaining to the selection of motor starters;
SAESs and SAMSSs.
SAES-P-113 Motors and Generator s
This SAES contains the minimum mandatory requirements for the procurement and
installation of induction motors. Any deviations from this standard must be approved by theSaudi Aramco Chief Engineer (Dhahran). This standard, in particular, lists the nominal
ratings (phases, voltages, hp/kW) for Saudi Aramco-procured motors.
SAES-P-114, Chapter 6, Motor Protection
This SAES (Chapter 6) specifies the minimum protection requirements for three-phase
motors. The chapter is categorized by motor type, voltage, and horsepower/kilowatt rating.
16-SAMSS-503 Low Voltage Motor Contr ol Center s and Switchr acks (600 V and
Below)
This SAMSS defines the minimum technical requirements for three-phase, 600 volts and
below, indoor motor control centers (MCC).
16-SAMSS-506 Medium Voltage Motor Contr ol Center
This SAMSS defines the minimum technical requirements for medium voltage (5 kV class)
metal-enclosed indoor motor control centers. This standard also applies to NEMA Class E2
current limiting fused controllers.
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Drawing 990-P-AB036766
This drawing describes the standard electrical symbols used for power one-line diagrams in
Saudi Aramco. Figure 6 lists several of the more common symbols that will be used in this
course. Again, as in most of the Saudi Aramco standards, the symbols are in accordance with
the more nationally recognized ANSI/IEEE Standard 315-1975.
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Figur e 6. Commonly Used Symbols for One-Line Diagrams
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GLOSSARY
ambient temper atur e The temperature of the medium such as air, water, or earth
into which the heat of the equipment is dissipated.
combinat ion star ter A complete motor starter consisting of a disconnect device, a
magnetic contactor, and protective devices for short circuit
and overload. All devices are assembled in a single
enclosure.
contactor A magnetic device that has sufficient capability to start and
stop a motor under normal and overload conditions.
continuous ra ting The maximum constant load that can be carried continuously
without exceeding established temperature-rise limitations
under prescribed conditions of test and within the limitationsof established standards.
disconnect switch A switch intended for isolating an electric circuit from the
source of power.
fault curr ent A current that results from the loss of insulation between
conductors or between a conductor and ground.
fault cur r ent, low-level A fault current that is equal to or less than the
(as applied to a motor maximum operating overload.
branch circuit)
interrupting capability The maximum value of current that a contact assembly is
required to successfully interrupt at a specified voltage for a
limited number of operations under specified conditions.
inverse time A qualifying term applied to a relay indicating that its time of
operation decreases as the magnitude of the operating
quantity increases.
motor circuit pr otector A magnetic-only molded case circuit breaker used
(MCP) in low voltage combination starters. This device has onlyinstantaneous functions to protect the motor, starter, and
branch circuit from short circuit and ground fault currents.
operat ing over load The overcurrent to which an electric apparatus is subjected in
the course of the normal operating conditions that it may
encounter.
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overload r elay A device that is used to sense an overload on a motor circuit.
The most common type uses a heater that heats a bi-metallic
strip that operates a set of contacts.
overload protection The effect of a device operative on excessive current, but not
necessarily on short circuit, to cause and maintain the
interruption of current flow to the governed device.
symmetr ical (curr ent) A currrent waveshape where the envelopes of the peaks are
symmetrical about the zero axis.