Technical collection

Circuit Breaker
Application Guide

05 – Motor Switching

Revision 2

November 2016

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1 Motor switching guide
1.1 Introduction

Electric motors are generally used in industrial processes or in traction

systems. In many motor applications it is required to make frequent
switching operations in order to respond a given application or industrial
process.

In MV applications the switching apparatus can be a contactor or a

circuit‐breaker, depending on the frequency of operations and the policy
adopted by the end user. The switching apparatus is increasingly based
on vacuum technology, which provides the following features:

Economical (cost vs number of switching operations)

Reliable (10 000 – 30 000 mechanical. cycles)

Higher Electrical Endurance than SF6 circuit‐breakers

Maintenance free

Long life

Relatively small sized

Environment friendly

Motor applications represent roughly 5% of the sales of commutating

devices in MV systems.

Motors can be synchronous and induction based. Synchronous motors

can be started via power electronics devices and in that case they do not
have any circuit‐breaker in series. However, starting of synchronous
motors can be also made direct on‐line. In this case the rotor is not
excited by a DC current, but the rotor field is created on specially
previewed rotor coils which are in short‐circuit. Therefore, in this case
the synchronous motor starting is similar to what happens with a real
induction machine, and there is a protection breaker upstream.

In general, whenever a machine is started by being connected to the

energy supply only through the stator, it can be assimilated to an
induction motor during the start and the considerations described in that
document fully apply.

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In the case of an induction machine, all the voltage applied on the
terminals is also applied on the motor internal impedance. This
impedance has a highly inductive nature. This is what makes motor
starting one of the applications requiring special attention since the
commutation on a motor, during its starting mode may lead to
overvoltages which could stress the insulation of the equipment and may
damage the motor in some instances.

Induction motors can be started directly on‐line, or through additional

equipment, being power electronics or autotransformer.

Starting through power electronics devices, such as soft‐starter, variable

speed drives, etc.., eliminates switching overvoltages from the circuit. In
fact, the presence of additional commutating devices, in series to the
circuit‐breaker, prevents development of the overvoltages.

The usage of autotransformer for the motor start will move the
overvoltages from the motor terminals to those of the transformer. Since
such applications are seldom, they are not covered by this guide.

When switching motors the user requires analysis of the potential

switching overvoltages, with sizing of the overvoltage protections that
may be needed. For help with this contact the Core Function Electrical
Networks Domain expert for analysis.

The creation of switching transient overvoltages is a normal phenomenon

during current interruption of a load. However, in the case of starting
motor interruption it can be amplified by the electrical nature of the
motor during his starting phase. This guide is focused on the switching
overvoltages on motors started directly on‐line. For direct on‐line started
motors, the situation is quite different. In fact a motor in its starting
mode can be considered as a highly inductive load.

1.2 Origins of the higher overvoltage during

motor start interruption
As it has been mentioned, a voltage transient is a natural way of the
system to adapt to the current interruption. For instance, in the case of
resistive load switching the voltage produced across the interrupter is
relatively low, often lower than the rated peak value of the system
voltage. This is due to the very small phase displacement between the
voltage and the current supplied to the load. Therefore the current
interruption, at zero crossing, is occurs when the voltage is also close to
its own zero crossing.

In the case of an induction machine, particularly in the beginning of the

starting period, the voltage and current are out of phase by almost 90°,
which means that when the current goes to zero the voltage will be at its

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maximum peak value. Therefore a sudden current interruption will be
followed by an overvoltage. The overvoltage transient is the natural way
of the system to adapt itself to this new “configuration”. The transient
obtained after current interruption is a function of several factors:

1. The motor and its feeder electrical characteristics: the equivalent

inductance and capacitance of the motor feeder determine a
frequency, natural frequency, at which the voltage at the motor
side of the circuit‐breaker will oscillate. This frequency is
considered limited up to 15kHz (IEC 62271‐110), in case of very
short connecting cables but in practice it is typically much lower.

2. The motor neutral earthing: the most common isolated neutral

will also lead to higher overvoltages

3. The commutation apparatus characteristics, in particular:

a. Chopped current of the interrupter.
This chopped current is a value at which the arc between the
contacts becomes unstable and is brutally interrupted.
Typically the chopped current varies around 0.5‐1 A for
contactors and, according to [1] is in the range of 2‐5.2 A, for
circuit‐breakers, of vacuum technology, with an average of
3.5 A. There are several reasons for this difference,
basically the different contact material, contactors being
designed for high mechanical and electrical endurance on
load current commutation, whereas circuit breakers are
intended for short‐circuit current interruption

b. Arc quenching capability

The arc quenching capability is “visible” during the
interruption of high frequency transients, which occur in case
of voltage escalation. Contactors have a lower capability and
from that perspective are likely to prolong the arc duration at
reignition, thus giving some more time for the dielectric
strength to grow. However this is not a reason to state that
contactors will always have lower overvoltages at motor start
interruption as their dielectric strength is lower compared to
that of circuit‐breakers

c. Dielectric strength of the interrupter

The dielectric strength is a parameter depending on the
size of the vacuum bottle and the opening speed. For
instance contactors have lower dielectric strength due to
smaller size and lower opening speed.

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The following mathematical expression gives the relationship between
the obtained overvoltage peak at the motor side of the interrupter and
the system/interrupter characteristics:

This peak in the voltage is produced at each interruption of the current. A

large part of the research done on vacuum circuit‐breakers relates to the
contact material alloy, which is in fact responsible for the chopped
current value. Up to this point these considerations can be applied to any
interrupter, disregarding its technology, simply the chopped current will
vary.

An example of such an overvoltage is presented below:

Voltage on motor side, interruption without reignitions

20

15 Interruption
in the next phase
10

0
V, [kV]

Interruption
in the first phase
-5

-10

-15 Transient Voltage oscillation

at natural frequency
-20

-25
0 2 4 6 8 10 12 14
t, [ms]

Figure 1 Overvoltage transient after current interruption

However, with vacuum technology there is additional phenomenon that

may take place, under certain conditions and strongly related to the
frequency of operations and especially opening during motor starting.
This is the phenomenon of multiple reignitions.

An example curve is provided on the Figure ‐2:

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 Voltage on motor side, interruption with reignitions and surge arrester
50

40
Voltage escalation
30

20

10

V, [kV]
0

-10 First current interruption Overvoltage limitation

and overvoltages by surge arrester
-20

-30
"Blinding"
-40 of the protection

-50
0 1 2 3 4 5 6 7 8 9 10
t, [ms]

Figure ‐2 Example of multiple reignitions after current interruption

On that figure the current interruption produces overvoltage which does

not achieve its prospective peak value, as on Figure 1. The arc reignites
shortly after the current extinction. This is due to the fact that the actual
dielectric strength developed between the contacts is lower than the
produced overvoltage. This happens only when contacts separate just
before the current interruption at zero. During the opening stroke of the
contacts until the moving contact reaches its final position the dielectric
strength of the open gap will increase as the physical separation of the
contacts increase. When the contacts reach the end of travel in their fully
open position the dielectric strength will be at its maximum value. But at
the beginning of contact travel it has a low value while the contact gap is
small, the dielectric strength of the gap shortly after contact separation
can be easily exceeded by the prospective transient overvoltage. If the
transient recovery voltage exceeds the dielectric strength of the gap then
a reignitions occurs.

The arc reignition means that a current will restart to flow between the
source and the motor. This current will have two components, one at
rated frequency and another which will have a much higher frequency
determined by the relevant network parameters during the current
interruption. One of the characteristics of the vacuum as an isolating
medium is to interrupt currents which have very steep front at zero. This

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characteristic will lead to an extinction of the arc current if it crosses
zero. The zero crossing will come from the high frequency transient
component of the current.

After each current interruption an overvoltage will be produced. It is

important to notice that due to the high frequency component of the
current, the chopped current value will not be the same as before with
the rated frequency signal. In fact the fast transient and the zero crossing
that it will produce will be “seen” by the motor feeder as a sudden
current interruption at higher chopped current. Therefore the following
overvoltage will have a higher prospective peak value.

The above described “loop” of current interruption and consecutive arc

reignition may repeat several times, with increasing amplitude of the
transient current and overvoltage. It will stop if either the dielectric
strength of the circuit‐breaker remains higher than the peak overvoltage
or there is overvoltage protection equipment that limits the overvoltages
and stops the sequence, or the current does not cross zero, if the rated
frequency current is higher than the transient.

It is important to note that voltage escalation is not systematic during

motor interruption. It is related to the following factors:

1. Instant of motor switch off with respect to the time elapsed from
start – the motor becomes more and more equivalent to a
resistance with speed increase, which modifies the phase shift
between current and voltage, i.e. if interruption occurs the
voltage will not be at its peak but on a smaller value
2. Instant of motor current interruption with respect to the time
elapsed from contact separation, meaning contacts of the
breaker poles. It has been observed that a time interval of more
than several hundreds of micro seconds will often allow the
dielectric strength to grow enough to withstand the first
overvoltage peak and slope and therefore interrupt without any
reignition.

Based on the above, the probability to have a voltage escalation with

damaging consequences remains low. However this does not mean that
overvoltage protection is not necessary. This probability, the status of the
dielectric insulation, the installation conditions and the importance of the
motor in the industrial process will however play a role on the selection
of protection means.

On Figure ‐2 it can be observed for a short period of time, that the

overvoltages are exceeding the limiting level of the surge arrester. This
delay of the surge arrester is a consequence of its performance and of its
installation conditions. Several meters of connecting cable can hold

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several kV of voltage drop at high frequencies thus the surge arrester
does not see the ‘true’ voltage on the motor terminals.

1.3 STANDARDISATION STATUS

In IEC 60071‐1:2006‐01 Table‐2 of dielectric withstand provides the
insulation levels for rated frequency signals. An extract of that table is
given below and the corresponding P.U values are provided in the last
column:

Highest Voltage for Standard rated short‐ Corresponding value in

the equipment duration power‐ pu of phase to earth
frequency withstand peak voltage
(Um) voltage
kV kV
(pu)
(rms value) (rms value)

3.6 10 4.81

7.2 20 4.81

12 28 4.04

TABLE 1 Standard insulation levels for applications 1kV‐245kV, at rated frequency, IEC
60071‐1

As it can be seen the required insulation level at rated frequency is often

above the value of 4.0pu and for the most common applications below
6.6kV rated voltage it goes as high as 4.8pu at rated frequency. This may
seem quite high, but it shall be kept in mind that at rated frequency the
voltage distribution along the stator winding is very regular. Therefore
the inter‐turn voltage remains relatively low. An increase in the
frequency will modify the voltage distribution along the stator winding
and tend to concentrate it to the first several turns. This, even at lower
overvoltages will lead to a higher stress of the inter‐turn insulation.

The prospective switching overvoltage level is defined for circuit breakers

switching reactive loads in the IEC 60071‐2:1996, as 3.0 p.u in case of
circuit –breakers with restrikes. This is a typical level with regards to the
fact that most of the public distribution networks, consisting of cables
and overhead lines are affected by rather low switching over‐voltages.

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However it does not mean that for motor switching the overvoltage will
be limited to a maximum of 3.0 p.u. if multiple reignitions occur.

Some withstand values of the overvoltage levels, as a function of the

impulse rise‐time are depicted on Figure ‐3:

Figure ‐3 Maximum motor withstand overvoltage level, 1992, 1

Another characteristic of higher frequency overvoltages is their

repetitiveness; in the case of multiple reignitions a motor insulation can
be damaged after multiple switching off operations during starting. This
is because it is frequently exposed to overvoltages with multiple
reignitions.

According to Figure ‐3, the maximum limitation level for motor switching
overvoltage protection can be fixed at 5.0pu. This is also somehow
compliant with the values used in rated frequency routine and type tests
given in TABLE 1. Such overvoltage limits imply that the motor is seldom
switched off during starting. So that probability of switching overvoltages
is low. This insulation level will be considered for the general
recommendations of protection means. A reduced level of 3.0pu will be
also discussed, since some protection solutions may limit the
overvoltages to even lower than 3.0pu levels. It will concern motors
frequently switched off during start.

1
R. Pretorius, "Guide for the Application of Switching Surge Suppressors to
Medium Voltage Motors", Electric Power Co-ordinating Committee, Aug. 1992

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 1.4 PROTECTION MEANS:

There are three major types of overvoltage protection solutions:

1. Surge arresters
2. Wave‐slopping capacitors (surge capacitors)
3. RC snubbers (resistance in series with capacitor)

The performance of the switching overvoltage protection, with respect to

the motor power and voltage is shown in Table 2.

Motor Motor Solution Solution

Power, Voltage, <3.0 pu <5.0 pu
kW kV
<300 3.3 Surge
<600 6.6 capacitor
<1000 11 Surge
>300 3.3 R‐C arrester
>600 6.6 branch
>1000 11
Table 2 gives suggested protection for motors

For more detail of overvoltage protection refer to dedicated chapter for

Overvoltage Protection (Guide 06 – Overvoltage Protection ).

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2 Guide for equipment selection

For each application where the circuit‐breaker is feeding a motor, then a

network calculation is required. Refer to enquiry sheet in appendix for
required parameters. Contact the core function Electrical Networks
Domain Expert for network study.

Selection of the above described protection means is made after several

considerations:

1.) It is necessary to protect the motor, not the circuit‐breaker which

normally has greater insulation level than the motor especially
for high frequency overvoltages
2.) Frequency of switching during motor start –the more frequent
the motor is supposed to be switched off during acceleration,
then higher the risk will be to observe a voltage escalation
3.) The space available for installation of overvoltage protection – it
is preferred to connect the protection device as close as possible
to the motor terminals. If connection of the protection device is
made at the circuit breaker, then a “downsizing” shall be applied,
it means that to get the same protection level a surge arrester on
the motor side should be replaced by capacitor or RC snubber
connected on the interrupter side.
4.) Prospective length of overvoltage protection cables –
effectiveness of surge arresters is greatly reduced with cables of
even 3m length
5.) Criticality of the motor for the industrial process and its cost of
refurbishment – big expensive motors or those where an outage
may lead to substantial production losses shall have the most
efficient protection, mostly it is an R‐C snubber
6.) Installation conditions – motors connected with long cables and
multiple cables per phase will have naturally a high capacitance
in front of them. The slope of the overvoltage will be decreased,
but the transients of one phase could be easily transmitted to the
other phases through this capacitive coupling. This may lead to a
“virtual” current chopping on these phases; the chopped current
may be of several hundreds of Amperes.
7.) Type of motor connecting cable: single core cables with screens
earthed at both sides would render the overvoltage protections
more effective. Multi‐core cables will be more favorable to
virtual current chopping since capacitances between cables of
different phases are higher.

In order to better understand some of the explanation below, the

following general electrical diagram shall be kept in mind:

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 Cable
M

Source Switchboard with Motor

VCB and protection

Figure 4 General scheme of the motor installation

Below some guidelines for overvoltage protection selection is given. The

overvoltage limitation level is given in P.U, whereas 1.0pu is equal to the
peak value of phase‐to‐earth voltage.

2.1.1 Surge arresters application, target limitation level

5.0 pu (For infrequent switching off during motor
starting):

2.1.1.1 Motors of starting current up to 1000 A:

Analyses of motor switching overvoltages show that surge arresters

would be very effective to guarantee a limitation below 5.0 times the
rated phase to earth peak voltage. This is a general conclusion including
system voltages from 3.3kV to 11kV. If the surge arrester is mounted on
the interrupter side, i.e. in the cubicle, then their effectiveness is limited
to applications with connecting cables shorter than 50m.

2.1.1.2 Motors of starting current up to 3000 A:

For such motors surge arresters will have a limited application due to the
physical arrangement of the connections. Their effectiveness will be also
related to the motor connecting cable length. They will be efficient for
cables whose equivalent phase to earth capacitance is higher than 350nF
(1km of cable, one conductor per phase).

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 2.1.2 Wave-slopping capacitors application, target
limitation level 3.0pu (frequently switching off
during motor starting):

2.1.2.1 Motors of starting current up to 1000 A:

Generally this solution is not applicable for motors above 300 A starting
current. In fact analyses show that the application of surge capacitors is
very dependent of motor starting current; a 500nF capacitor will reduce
overvoltages to 3.0pu for motors of less than 300A starting current, for
system voltage of 3.3kV and 100A for motors at 11kV (around 500kW at
11kV).

Therefore this type of solution will be reserved to applications with very

small motors.

The connection of the protection, motor side or interrupter side will not
have an impact on the effectiveness of this solution.

Note that surge capacitors have very binary effectiveness: they will either
limit the overvoltages very low, up to 3.0pu, or they could contribute to
voltage escalation and virtual current chopping between phases.

2.1.3 R-C snubber applications, variable target

limitation level:

2.1.3.1 Motors of starting current up to 3000 A:

2.1.3.1.1 Limitation up to 3.0pu:

Effectiveness of R‐C snubber is proven in case of connection on the
motor terminals or very close. This is not influenced by motor size or
system voltage or by the cable length. Limitations appear for multi‐core
cables when unearthed on the motor side and multi‐core cables.
Effectiveness is subject to conditions when mounted on the interrupter
side.

2.1.3.1.2 Limitation up to 5.0pu:

This higher tolerated overvoltage level releases some constraints on the
installation conditions of the R‐C snubber, it can be achieved with
connection on the interrupter side. Some limitations appear for voltages
above 6.6kV. In fewer cases cable type and screen connections may
influence the effectiveness of this protection solution.

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Reference documents:
[1] IEC 60071-1: Insulation co-ordination – Part 1: Definitions,
principles and rules

[2] IEC 60071-2: Insulation co-ordination – Part 2: Application guide

[3] Overvoltage Protection Study On Vacuum Breaker Switched MV

Motors: Petroleum and Chemical Industry Committee Europe, 2008, D.
Penkov, C. Vollet, B. De Metz-Noblat, R. Nikodem

[4] Overvoltages and insulation coordination in MV and HV: D.

Fulchiron, Cahier Technique Merlin Gerin n° 151

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 APPENDIX 1: INQUIRY SHEET

Date:
Project name:

Project leader:

Feeder circuit:
Short‐circuit power: ................................................ MVA
Rated operating voltage:......................................... kV
Rated frequency: ..................................................... Hz
Neutral earthing factor: ...........................................
Duration of earth fault current: ............................... s

Connection step‐up transformer & CB(s):

Cable/Bus type(#/phase, single/multi‐core):………
Cross‐section: ........................................................... mm2
Length: ..................................................................... m

Connection CB and motor:

Cable/Bus type (#/phase, single/multi‐core)………
Cross‐section: ........................................................... mm2
Length: ..................................................................... m
Screens earthing (1 side, specify which, both) ……..

Power factor capacitor or surge arrester installed:

C= ............................................................................. µF
ZnO type = ................................................................
Installed at motor or interrupter side: .....................

M Motor(s):
Rated apparent power: ............................................ MVA
Rated active power: ................................................. MW
Rated voltage: .......................................................... kV
Rotation speed: ........................................................ rpm

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