Overload Relays and Thermal Unit Selection Class 9065 CONTENTS Description Page General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 Approximate Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17 Thermal Unit Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description INTRODUCTION Overload relays are intended to protect motors, controllers, and branch-circuit conductors against excessive heating due to prolonged motor overcurrents up to and including locked rotor currents. Protection of the motor and the other branch-circuit components from higher currents, due to short circuits or grounds, is a function of the branch-circuit fuses, circuit breakers, or motor short-circuit protectors. Electrical motors make up a large percentage of power system loads.
Product Description IEC components are typically application rated. This means the controller is sized very close to its operational limit for a given application. IEC motors are also generally more application rated. For these reasons, Class 10 trip is most common on IEC applications. Because NEMA products are applied with more built-in excess capacity, the Class 20 trip is most common. Figure 1 shows the three types of trip curves. 10000.0 Class 10 Class 20 Class 30 Trip Times (s) 1000.0 100.0 10.
Product Description At current values greater than Ic, the SCPD reacts quicker than the overload relay. At current values less than Ic, the overload relay reacts quicker. Articles 110 and 430 of the NEC provide guidance in the selection of the SCPD to facilitate coordination of the components of a motor branch circuit (i.e. location of point Ic). Thermal Relay Unit Motor Withstand Ratings Magnet Coil Drawing shows operation of melting alloy overload relay.
Product Description solder pot are combined in a one piece, nontamperable unit. Melting alloy thermal overload relays must be reset by a deliberate hand operation after they trip. A reset button is usually mounted on the cover of enclosed starters. Thermal units are rated in amperes and are selected on the basis of motor full load current, not horsepower.
Product Description thermal units for repair or replacement. Not having to install thermal units can save from 20-30% of the installation time for a starter or separate overload relay, as compared to the traditional NEMA devices. The solid state device, when operated within its operating temperature range, does not require ambient compensation. Only the level of current being drawn by the motor affects the trip of the device.
Thermal Overload Relays – NEMA Rated Melting Alloy NEMA-rated Thermal Overload Relays feature: • Exclusive One-Piece Thermal Unit • Trip Free Reset Mechanism on Types F, G & S • Inverse Time Delay Trip • Replaceable Contact Units on Types F, G & S • Alarm Contact Available Slow trip (Class 30) and quick trip (Class 10) melting alloy thermal units are available for all Size 1, 2, 5 and 6, and some Size 3 and 4 applications. Thermal units are not included.
Thermal Overload Relays – NEMA Rated Bimetallic Bimetallic thermal overload relays feature automatic reset or hand reset and a trip-free mechanism. There are ambient temperature-compensated versions. Note that thermal units are not included in the shown prices.
Thermal Overload Relays – NEMA Rated Solid State Overload Relay, Motor Logic™ Base Unit Base Unit relays feature: 3 to 1 adjustment range for trip current; phase loss and unbalance protection; direct replacement for Type S melting alloy; and LED power indication. They are ambient insensitive and self–powered. Electrical remote reset is also available.
Thermal Overload Relays – NEMA Rated Solid State Overload Relay, Motor Logic™ Feature Base Unit Feature Unit relays include all of the features found on the Base Unit relays plus: switch selectable trip class; Class II ground fault detection; and direct replacement for Type S melting alloy. These relays will also accept the Analog Output Module or Seriplex® communication module. Electrical remote reset is also available.
Thermal Overload Relays – NEMA Rated Application Data General Overload relays are intended to protect motors, controllers, and branch-circuit conductors against excessive heating due to prolonged motor overcurrents up to and including locked rotor currents. Protection of the motor and the other branch-circuit components from higher currents, due to short circuits or grounds, is a function of the branch-circuit fuses, circuit breakers, or motor short-circuit protectors.
Thermal Overload Relays – NEMA Rated Application Data Once tripped, the thermal overload relay will not reset until it has cooled, automatically allowing the motor to cool before it can be re-started. Cutaway View of Standard Trip Melting Alloy Thermal Unit Square D manufactures two basic types of thermal overload relays, the melting alloy and the bimetallic. In some types, the bimetallic is available in both non-compensated and ambient temperature-compensated versions.
Thermal Overload Relays – NEMA Rated Application Data Power Circuit Voltage Ratings Type AC — 50 or 60 Hz DC C, F, G, T, U 600 600 A, S 600 — AF, AG, AR, AT, AU 600 600 AC — 50 or 60 Hz Type AD, AG, AR, AT, AU, C, F, G, T, U, SAF, SAG, SAU, SDO18 SS, SSF, SR, ST DC Volts (Minimum NEMA of Contact 110 volts Ratings is recommended) A600 SD & SE (Sizes 0-4 & 6), Class 9998 Type SO1 and Class 9999 Type SO4 B600 and SO5 Contact Modules 120 240 480 600 120 240 480 600 Inductive 35% Power Factor
Thermal Overload Relays – NEMA Rated Application Data Remote Reset Module The Remote Reset Module can be easily field installed on solid state overload relays. This module will allow the overload relay to be reset from a remote location.
Thermal Overload Relays – NEMA Rated Approximate Dimensions Melting Alloy Type NEMA Style G E F Dimensions H Shipping Weight (Lbs) Type A B C D E F G H I J K L M N O P A K B I SEO5 35/16 — 15/ 32 331/32 317/32 213/16 7/ 32 11/ 16 25/16 1/ 2 1/ 2 1/ 2 27/ 32 1 13/8 #10 1 SEO8 35/16 — 15/ 32 331/32 31/2 213/16 3/ 16 11/ 16 25/16 1/ 2 1/ 2 1/ 2 27/ 32 1 13/8 #10 11/4 RESET J L C M D Prov. for (4) – P – Mtg.
Thermal Overload Relays – NEMA Rated Approximate Dimensions Bimetallic Overload Relays 3.50 3.75 89 95 2.81 .50 71 13 71 13 2.81 .50 3.34 3.59 85 91 2.30 2.30 Reset 58 Reset 58 .80 .80 20 20 2 .89 1.00 23 25 .89 1.00 3.94 Prov. for (4) #10 Mounting Screws 8 2 8 Travel 8 .31 .06 .31 Reset .31 .06 23 100 Types SEO6B and SEO6B2 Weight — 1 Lb .31 Reset 8 Travel 3.94 Prov.
Thermal Overload Relays – NEMA Rated Approximate Dimensions Motor Logic™ – Solid State Overload Relay (2) Holes. (2) Slots for 8-32 Mtg. Screws 2.81 71 4.28 109 .31 8 3.91 99 2.69 2.23 68 57 RESET .27 25 7 1.59 40 .36 6 Travel .28 3.24 82 RESET 3.90 7 89 56 47 1.24 99 31 9 .89 23 43 .24 Reset 3.51 2.19 1.70 1.84 1.00 .24 Reset 1.24 3.26 6 Travel 31 83 NEMA Size 00B, 00C, 0, and 1 Devices 0.00 00 NEMA Size 2 Devices 5.32 135 4.74 5.32 135 3.25 4.74 83 120 .
Overload Relay Comparison OVERLOAD RELAY COMPARISON Information is subject to change without notice. Overload Relay Type Allen Bradley Bulletin 592/593 Series Trip Indication Reset Mechanism Solid State Overload Melting Alloy Bulletin 592 Yes, an optical indicator which turns yellow. Manual Only Bimetallic Bulletin 593 Yes, an optical indicator which turns yellow. Automatic • • • • • Solid State Bulletin 592 SMP1, SMP2, SMP3 Yes, yellow trip flag appears in window.
Thermal Unit Selection 1. Determine motor data: a. Full load current rating b. Service factor NOTE: If motor full load current is not known, a tentative thermal unit selection could be made, based on horsepower and voltage. Refer to Page 22. 2. Motor and controller in same ambient temperature: a. All starter classes, except Class 8198: 1. For 1.15 to 1.25 service factor motors use 100% of motor full load current for thermal unit selection. 2. For 1.
Thermal Unit Selection Quick Trip Thermal Unit Selection To select Type FB quick blow trip thermal units, the selection table for a standard Type B thermal unit may be used with the following modifications: for continuous rated motors having service factors of 1.15 to 1.25, select thermal units from the standard Type B table using 93% (102% for Class 8198) of the full load current shown on the motor nameplate and then substitute a FB for the B in the thermal unit type number.
Thermal Unit Selection Thermal Unit Selection Table Number Controller Hand Reset Melting Alloy Bimetallic Starter Type Class Type tSeries Size Standard Trip (20) Quick Trip (10) Slow Trip (30) NonCompenCompensated sated Manual Starters FHP 2510 2512 8908 F A FHP 43a .... .... .... .... Manual Starters (Small Enclosure) 2510 M, T A M-0 M-1 M-1P 1 1 1 72 72 72 X X X .... .... .... .... .... ....
Thermal Unit Selection Controller Starter Type AC Magnetic Starters (Large Enclosure) Class Type tSeries Size 8198 8536 (Starter Used in Multi-Motor Panel) 8538 8904c 8539 8906 8606 8907 8630k 8920 8640q 8922 9089 8924 8647 8925 8650 8930 8736 8941 8738 8739 G, S A (8536 only) SA SB SC SD SG .... B, C A, B A A A A B A B A .... 00 00 0 1 2 3 3 4 4 5 5 14a 53 15 15 58 16 .... 61 .... 24e .... .... .... 78 78 79 80h .... 81h .... .... X .... X X X X 133hX .... .... .... .... SH A 6 20 ....
Thermal Unit Selection CALCULATION OF TRIP CURRENT RATING Trip Current Rating – Trip current rating is a nominal value which approximates the minimum current to trip an overload relay in an ambient temperature, outside of the enclosure, of 40°C (104°F). In all selection tables, except Class 8198 the trip current rating is 1.25 times the minimum full load current shown for the thermal unit selected. For Class 8198, the trip current rating is 1.15 times the minimum full load current.
Thermal Unit Selection APPROXIMATE THERMAL UNIT SELECTION BASED ON HORSEPOWER AND VOLTAGE General Thermal units selected using approximate full load currents from the table below will provide a trip current between 101% and 125% of full load current for many 4-pole, single speed, normal torque, 60 Hz motors. Since full load current rating of different makes and types of motors vary so widely, these selections may not be suitable.
Thermal Unit Selection Tables 1 thru 6 Table 1 Table 2 Motor Full-Load Current (Amp) Table 3 Motor Full-Load Current (Amp) Table 4 Motor Full-Load Current (Amp) Motor Full-Load Current (Amp) 1 T.U. 3 T.U. Thermal Unit Number 1 T.U. 3 T.U. Thermal Unit Number 1 T.U. 3 T.U. Thermal Unit Number 1 T.U. 3 T.U. Thermal Unit Number 0.33-0.36 0.37-0.40 0.41-0.45 0.46-0.52 0.53-0.59 0.29-0.32 0.33-0.36 0.37-0.39 0.40-0.47 0.48-0.56 B B B B B 0.44 0.51 0.57 0.63 0.71 0.35-0.38 0.39-0.43 0.
Thermal Unit Selection Tables 7 thru 12 Table 8 Table 7 Polyphase Single Phase Motor Full-Load Current (Amp) Maximum Fuse Rating (Amp) Maximum Fuse Rating (Amp) Single PH Motor FullLoad Current (Amp) Thermal Unit No. 0.33-0.36 0.37-.040 0.41-0.45 0.46-0.52 0.53-0.59 B B B B B 0.44 0.51 0.57 0.63 0.71 0.60-0.66 0.67-0.73 0.74-0.81 0.82-0.91 0.92-1.02 B B B B B 1.03-1.14 1.15-1.29 1.30-1.42 1.43-1.64 1.65-1.80 SingleMotor Installation (N.E.C. 430-52) Group Motor Installation (N.E.C.
Thermal Unit Selection Tables 13 thru 18 Table 13 Table 14 Motor Full-Load Current (Amp) Table 15 Motor Full-Load Current (Amp) Motor Full-Load Current (Amp) 1.T.U. 2 T.U. 3 T.U. Thermal Unit Number 1.T.U. 2 T.U. 3 T.U. Thermal Unit Number 1.T.U. 2 T.U. 3 T.U. Thermal Unit Number 0.29-0.31 0.32-0.34 0.65-0.38 0.39-0.45 0.46-0.54 0.29-0.31 0.32-0.34 0.35-0.38 0.39-0.45 0.46-0.54 0.28-0.30 0.31-0.34 0.35-0.37 0.38-0.44 0.45-0.53 B B B B B 0.44 0.51 0.57 0.63 0.71 0.43-0.47 0.48-0.51 0.
Thermal Unit Selection Tables 19 thru 30 Table 19 Motor Full-Load Current (Amp) Table 20 Table 22 Table 21 Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Load Motor Full-Load Current (Amp) Thermal Unit Number 133.-148. 149.-174. 175.-195. 196.-219. 220.-239. B 1.30 B 1.45 B 1.67 B 1.88 B 2.10 128.140. 141.-163. 164.-179 1.80-201. 202.-227. B 1.30 B 1.45 B 1.67 B 1.88 B 2.01 92.0-100. 101.-109. 110.-119. 120.-131. 132.-139. DD 112 DD 121 DD 128 DD 140 DD 150 CC 81.5 CC 87.
Thermal Unit Selection Tables 31 thru 41 Table 31 Table 32 Table 33 Table 34 Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number 0.31-0.35 0.36-0.39 0.40-0.44 B 0.44 B 0.51 B 0.57 0.45-0.50 0.51-0.61 0.62-0.68 B 0.63 B 0.71 B 0.81 0.33-0.35 0.36-0.39 0.40-0.42 0.43-0.46 0.47-0.51 AR .45 AR .49 AR .54 AR .59 AR .65 0.28-0.30 0.31-0.33 0.34-0.
Thermal Unit Selection Tables 42 thru 52 Table 42 Table 43 Table 44 Table 45 Motor Full-Load Current (Amp) Thermal Unit Number Motor Thermal Full-Load Unit Current (Amp.) Number Motor Full-Load Current (Amp) Thermal Unit Number Size 7 Size 8 Type J Type K 0.28-0.30 0.31-0.33 0.34-0.36 0.37-0.39 0.40-0.42 AR .45 AR .49 AR .54 AR .59 AR .65 0.41-0.44 0.45-0.49 0.50-0.53 0.54-0.58 0.59-0.65 A A A A A .49 .54 .59 .65 .71 0.34-0.38 0.39-0.43 0.44-0.48 0.49-0.53 0.54-0.62 B 0.44 B 0.51 B 0.
Thermal Unit Selection Tables 53 thru 63 Table 53 Motor Full-Load Current (Amp) Table 54 Table 55 Motor Full-Load Current (Amp) 3 T. U. Thermal Unit Number Motor Load-Full Current (Amp) 2 T. U. 2 T. U. Table 56 Motor Full-Load Current (Amp) 3 T. U. Thermal Unit Number 1 or 2 T. U. 3 T. U. Thermal Unit Number 1 T. U. 3 T. U. Thermal Unit Number 0.31-0.33 0.34-0.36 0.37-0.40 0.41-0.48 0.49-0.57 0.29-0.31 0.32-0.36 0.37-0.38 0.39-0.46 0.47-0.55 B 0.44 B 0.51 B 0.57 B 0.63 B 0.71 43.6-45.
Thermal Unit Selection Tables 64 thru 71 Table 64 Table 65 Motor Full-Load Current (Amp.) 2 T. U. 1 PH 2 T. U. 2 PH 3 T. U. Thermal Unit Number 0.38-0.40 0.41-0.43 0.44-0.48 0.49-0.52 0.53-0.56 0.38-0.40 0.41-0.43 0.44-0.48 0.49-0.52 0.53-0.56 0.31-0.33 0.34-0.36 0.37-0.39 0.40-0.43 0.44-0.47 AR .45 AR .49 AR .54 AR .59 AR .65 0.57-0.61 0.62-0.67 0.68-0.73 0.74-0.81 0.82-0.89 0.57-0.61 0.62-0.67 0.68-0.73 0.74-0.81 0.82-0.89 0.48-0.51 0.52-0.56 0.57-0.58 0.59-0.64 0.65-0.70 AR .71 AR .78 AR .
Thermal Unit Selection Tables 72 thru 77 Table 73 Table 72 Motor Full-Load Current (Amp) 1 T. U. 3 T. U. Thermal Unit Number Motor Full-Load Current (Amp) 1 T. U. 3 T. U. Table 74 Thermal Unit Number Motor Full-Load Current (Amp) 1 T. U. 3 T. U. Table 75 Thermal Unit Number 2.38-2.62 2.38-2.62 FB 3.33 2.63-2.94 2.63-2.94 FB 3.71 2.95-3.31 2.95-3.31 FB 4.1 2.42-2.67 2.42-2.67 FB 3.33 2.68-3.00 2.68-3.00 FB 3.71 3.01-3.36 3.01-3.36 FB 4.1 2.23-2.47 2.23-2.47 FB 3.33 2.48-2.76 2.48-2.76 FB 3.71 2.
Thermal Unit Selection Tables 78 thru 83 Table 78 Motor Full-Load Current (Amp) 1 T. U. 2 T. U. or 3 T. U. Table 79 Thermal Unit Number 2.26-2.51 2.26-2.51 FB 3.33 2.52-2.82 2.52-2.82 FB 3.71 2.83-3.09 2.83-3.09 FB 4.1 3.10-3.30 3.10-3.30 FB 4.5 3.31-3.69 3.31-3.69 FB 4.75 3.70-4.27 3.70-4.27 FB 5.3 4.28-4.72 4.28-4.72 FB 6.1 4.73-5.25 4.73-5.25 FB 6.75 5.26-5.53 5.26-5.53 FB 7.45 5.54-5.81 5.54-5.81 FB 7.8 5.82-6.14 5.82-6.14 FB 8.21 6.15-6.44 6.15-6.44 FB 8.6 6.45-6.81 6.45-6.81 FB 9.0 6.82-7.19 6.
Thermal Unit Selection Tables 84 thru 91 Table 86 Table 84 Table 87 Table 88 Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number 3.38-3.78 3.79-4.37 4.38-4.87 FB 4.75 FB 5.3 FB 6.1 0.43-0.44 0.45-0.47 0.48-0.53 A .49 A .54 A .59 0.40-0.41 0.42-0.45 0.46-0.51 A .49 A .54 A .59 0.39-0.40 0.41-0.44 0.45-0.49 A .49 A .54 A .59 4.88-5.51 5.52-5.
Thermal Unit Selection Tables 92 thru 101 Table 92 Table 93 Table 94 Table 95 Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number 10.5-11.7 11.8-12.5 12.6-14.0 B 17.5 B 19.5 B 22 23.8-25.2 25.3-26.8 26.9-28.4 CC 36.4 CC 39.6 CC 42.7 25.8-27.5 27.6-29.4 29.5-31.4 CC 36.4 CC 39.6 CC 42.7 42.5-44.7 44.8-47.9 48.0-51.2 CC 64.3 CC 68.5 CC 74.6 14.
Thermal Unit Selection Tables 102 thru 110 Table 102 Table 103 Table 104 Table 105 Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number 146-169 170-185 186-201 AR 1.68 AR 1.85 AR 2.04 0.57-0.60 0.61-0.66 0.67-0.73 AR 1.05 AR 1.15 AR 1.26 4.24-4.62 4.63-5.05 5.06-5.54 AR 8.5 AR 9.3 AR 10.2 27.1-30.0 30.1-33.2 33.3-35.
Thermal Unit Selection Tables 111 thru 120 Table 111 Table 112 Table 113 Table 114 Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number 14.0-14.9 15.0-16.2 16.3-17.2 17.3-18.7 18.8-20.2 CC 20.9 CC 22.8 CC 24.6 CC 26.3 CC 28.8 44.0-46.8 46.9-50.6 50.7-54.5 54.6-58.4 58.5-62.9 CC 64.3 CC 68.5 CC 74.6 CC 81.5 CC 87.7 88.2-95.1 95.
Thermal Unit Selection Tables 121 thru 128 Table 121 Table 122 Table 123 Table 124 Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number Motor Full-Load Current (Amp) Thermal Unit Number 1.14-1.21 1.22-1.33 1.34-1.47 AR 1.05 AR 1.15 AR 1.26 8.48-9.25 9.26-10.11 10.12-11.09 AR 8.5 AR 9.3 AR 10.2 54.2-60.1 60.2-66.5 66.6-71.5 E 67 E 69 E 70 1.14-1.21 1.22-1.33 1.34-1.47 AR 1.05 AR 1.15 AR 1.
Thermal Unit Selection Tables 129 thru 136 Table 129 Table 130 Table 131 Table 132 Motor Full-load Current (Amp) Thermal Unit Number Motor Full-load Current (Amp) Thermal Unit Number Motor Full-load Current (Amp) Thermal Unit Number Motor Full-load Current (Amp) Thermal Unit Number 28.0-29.2 30.0-32.5 32.6-34.5 34.6-37.5 CC 20.9 CC 22.8 CC 24.6 CC 26.3 1.12-1.27 1.28-1.37 1.38-1.55 1.56-1.71 B 0.81 B 0.92 B 1.03 B 1.16 7.88-8.91 8.92-9.95 9.96-10.57 10.58-11.95 B 6.90 B 7.70 B 8.20 B 9.
Thermal Unit Selection Tables 137 thru 144 \ Table 137 Table 138 Table 139 Table 140 Motor Full-load Current (Amp) Thermal Unit Number Motor Full-load Current (Amp) Thermal Unit Number Motor Full-load Current (Amp) Thermal Unit Number Motor Full-load Current (Amp) Thermal Unit Number 50-55.9 56-60.9 61-65.9 66-69.9 E 88 E 89 E 91 E 92 22.6-25.5 25.6-26.4 26.5-28.9 29.0-31.9 E 62 E 65 E 66 E 67 13.7-15.2 15.3-16.8 16.9-18.7 18.8-20.0 E 57 E 59 E 60 E 61 0.34-0.36 0.37-0.40 0.41-0.43 0.
Thermal Unit Selection Tables 145 thru 148 Table 145 Table 146 Table 147 Motor Full-load Current (Amp) Motor Full-load Current (Amp) 1 T.U. 3 T.U. Thermal Unit Number Motor Full-load Current (Amp) 1 T.U. Table 148 Motor Full-load Current (Amp) 3 T.U. Thermal Unit Number 1 T.U. 3 T.U. Thermal Unit Number 1 T.U. 3 T.U. Thermal Unit Number 1.00-1.11 1.12-1.27 1.28-1.36 1.37-1.53 0.91-1.02 1.03-1.15 1.16-1.27 1.28-1.39 B1.30 B1.45 B1.67 B1.88 3.90-4.22 4.23-4.49 4.50-5.14 5.15-5.78 3.60-3.
Square D Company 8001 Highway 64 East Knightdale, NC 27545-9023 (919) 266-3671 INNOVA and ESP100 are registered trademarks of Furnas Electric Company. ADVANTAGE is a registered trademark of Eaton Corporation. MOTOR LOGIC is a trademark of Square D Company. SERIPLEX, Square D and are registered trademarks of Square D Company. Catalog No. 9065CT9701 May 1998 © 1998 Square D All Rights Reserved.