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Gas Recirculation Fan Motor Overload Sizing

06/12/2008 12:55 PM

A 200 HP, 460 V motor drives a fan designed to recirculate exhaust gas for use in atomizing and distributing aqueous ammonia over an SCR catalyst. The fan motor is rated at 226 Amps with a service factor of 1.15. The motor is designed for 18 seconds of locked rotor current to accomodate fan run-up. With inlet and outlet dampers shut the fans take 12 to 14 seconds to come up to speed, current during this period is > 1500 amps, tails to 300 amps for 2 to 3 seconds and finally steadies at 114 amps with no flow through the fan. Overload heaters, C13.7B or C15.1B (oversized) open during this start sequence. What type of overload heater should be used in this application when initial long duration inrush currents are expected. Motor data follows below. Please be explicit as I am electrically declined (flangehead).

HP: 200 3PH

Duty: Cont. AMB: 40 C

Class Insul: F

S.F.: 1.15

Volts: 460

Nema Design: B

kVA Code: G

Amps: 226.0

Temp Rise: Class B

RPM: 1785 Hz: 60

Nema Nom Eff: 96.2%

Guaranteed Min. Eff.: 95.4%

Weight: 2035 lbs.

Meets IEEE Std. 841-2001

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#1

Re: Gas Recirculation Fan Motor Overload Sizing

06/12/2008 2:26 PM

You should never over size the overload heater elements to allow for acceleration, unless you have two separate OL relays and logic to switch between them once the motor is at full speed. OL heater selection is done to prevent a fire. Over sizing them may allow severe insulation damage and / or a fire under running overload conditions.

The typical solution is to have a bypass relay on the overload circuit, controlled by a timer and an acceleration detection system (speed switch typically). On a start command, a timer is energized, which immediately closes a small contactor that bypasses (shorts) the OL CT current so that the relay doesn't see it. The timer is set to the maximum acceleration time of the motor, in your case 18 seconds. If the speed detection system is satisfied within the 18 seconds, the timer is opened and the shorting contactor is opened, so the OL relay is then in the circuit protecting the motor. If the speed detection is not satisfied in 18 seconds, the timer's timed contact changes state and locks out the starting circuit, shutting down the motor starter.

If you are in the US (assuming so by your use of HP instead of kW), the NEC allows for this kind of procedure on high inertia loads. I cannot speak to other countries' codes.

At that HP however, you should consider using a good solid state soft starter. Many of them have this kind of functionality built in to their solid state overload protection scheme since they are often used to control hard to accelerate loads like yours.

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#3
In reply to #1

Re: Gas Recirculation Fan Motor Overload Sizing

06/12/2008 2:54 PM

Hello JRaef

from me

Kind Regards....

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#2

Re: Gas Recirculation Fan Motor Overload Sizing

06/12/2008 2:52 PM

Hello ducatidude

As mentioned by JRaef above, you are safer to use an electronic type soft starter.

Kind Regards....

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