DOCUMENT NUMBER TP - 10 - 002

PAGE NUMBER Page 1

PREPARED BY JOEY M. TORAL
DOCUMENT NAME DESIGN STANDARDS MANUAL APPROVED BY JOEY M. TORAL
DOCUMENT SECTION TECHNICAL PROCEDURE SUBJECT BOILER CONTROLS
TITLE MOTORS AND MOTOR CONTROLS SPECIFICATIONS (COMPARTMENTALIZED)

TABLE OF CONTENTS

1. OBJECTIVE

2. SUPPLY MAINS

2.1 GENERAL
2.2 BUS BARS
2.3 MAIN BREAKERS AND FEEDERS

3. MOTORS AND MOTOR BRANCH CIRCUITS

3.1 MOTORS
3.2 MOTOR STARTING
3.3 MOTOR BRANCH CIRCUITS

4. INSTRUMENT FEEDER LINES

5. CONTROL PANEL

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PAGE NUMBER Page 2
PREPARED BY JOEY M. TORAL
DOCUMENT NAME DESIGN STANDARDS MANUAL APPROVED BY JOEY M. TORAL
DOCUMENT SECTION TECHNICAL PROCEDURE SUBJECT BOILER CONTROLS
TITLE MOTORS AND MOTOR CONTROLS SPECIFICATIONS (COMPARTMENTALIZED)

1. OBJECTIVE

This specification covers motors and motor controls housed inside a boiler control panel. It is not the
intention of this specification to replace totally the relevant electrical code requirements but to
conceptualise them in a more standard manner. Any discrepancy on this specification with any electrical
code or client's specifications the more stringent will apply.

2. SUPPLY MAINS

2.1. GENERAL
General sizing of main bus or main breakers should be calculated by the following formula:

M = 1.25 x (ΣIl + ΣIm + (1.25 x Imo)) x (1 + G/100)

Where:
M - Rating of main lugs or overcurrent device, Amps
ΣIl - Sum of all auxiliary loads, Amps
ΣIm - Sum of all motor FLC except largest motor, Amps
Imo - FLC of largest motor, Amps
G - Growth Factor, % (should be 100% unless otherwise specified)
FLC - Full load current

2.2. BUS BARS

2.2.1. Bus bars should be of copper material.

2.2.2. Bus bars should run through the whole length of the control panel.

2.2.3. Maximum current density on bus bars should be limited to 1000 Amps/in2.

2.2.4. Creepage distance should be maintained at 50-mm minimum between phases of bus bars.

2.2.5. Branches and taps on main bus bars should be supported rigidly on insulators preferably of
glass polyester material.

2.2.6. All bolted connections shall be provided with locknuts.

2.2.7. Supports for bus bars should be placed at frequent intervals to prevent deformation when fault
occurs or damage during shipment.

2.3. MAIN BREAKERS AND FEEDERS

2.3.1. Main breakers should have ground fault protection by using a ground fault sensor control
transformer and a ground fault relay activating a shunt trip mechanism.

2.3.2. Main breakers should offer overload and short circuit protection.

2.3.3. An ammeter shall be provided and should be able to monitor the current reading in all phases
by a rotary ammeter switch. Ammeter should be of the current transformer type.

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PAGE NUMBER Page 3
PREPARED BY JOEY M. TORAL
DOCUMENT NAME DESIGN STANDARDS MANUAL APPROVED BY JOEY M. TORAL
DOCUMENT SECTION TECHNICAL PROCEDURE SUBJECT BOILER CONTROLS
TITLE MOTORS AND MOTOR CONTROLS SPECIFICATIONS (COMPARTMENTALIZED)

2.3.4. A voltmeter shall also be provided and should be able to monitor the potential in between
phases by a rotary voltmeter switch. Three indicating lights shall be provided, R-W-B. Three
potential fuses shall also be provided.

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 DOCUMENT NUMBER TP - 10 - 002
PAGE NUMBER Page 4
PREPARED BY JOEY M. TORAL
DOCUMENT NAME DESIGN STANDARDS MANUAL APPROVED BY JOEY M. TORAL
DOCUMENT SECTION TECHNICAL PROCEDURE SUBJECT BOILER CONTROLS
TITLE MOTORS AND MOTOR CONTROLS SPECIFICATIONS (COMPARTMENTALIZED)

3. MOTORS AND MOTOR BRANCH CIRCUITS

3.1. MOTORS

3.1.1. Motors should conform to NEMA or IEC standards and can either be of aluminum or steel
frame, totally enclosed and fan cooled.

3.1.2. Wound rotor or slip ring motors should be limited to motor speeds not more than 1000 rpm.
Beyond 1000 rpm a squirrel cage motor should be definitely used.

3.2. MOTOR STARTING

3.2.1. For motors rated at 4 kW and below direct-on-line starting should be applied. Refer to Table No
2 for motor contactor sizes.

3.2.2. For motors rated 5.5 kW and above starting method can either be of the star-delta, auto-
transformer, or rotor resistance depending on the type of motor used, the type of driven
equipment, and the availability of supply power.

3.2.3. When using the star-delta starting method it should be of the open transition type. Refer to
Table No 3 for contactor sizes.

3.2.4. When using the auto-transformer starting method it should be of the three-leg closed transition
type. Refer to Table No 4 for contactor sizes.

3.2.5. Maximum starting time for auto-transformer circuits should be about 10 seconds. Maximum
starting cycles should be about 8 starts per hour.

3.2.6. Auto-transformers should be protected by inherent thermal protectors and they should be
interlocked on the motor starting circuit.

3.2.7. Slip ring motors not over 56 kW should have at least three acceleration stages during starting
while those over 56 kW should have at least four acceleration stages depending on availability
of supply power.

3.2.8. Resistors for rotor-resistance starting should be sized up for start-up service only. Maximum
starting cycles is about 10 starts per hour.

3.2.9. Motors should be provided with stop & start push button switches, run & trip indicating lights,
and MIMIC panel on and off indicating lamps.

3.2.10. Motor contactors should be selected with the following utilisation categories to IEC publication
158-1:
a.) AC-2 for Slip-ring motors normal motor starting and/or plugging.

b.) AC-3 for Squirrel cage motors normal motor starting and/or switching off during
running. Refer to Table No 1 for contactor ratings.

c.) AC-4 for Squirrel cage motors plugging, reversing, or inching.

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 DOCUMENT NUMBER TP - 10 - 002
PAGE NUMBER Page 5
PREPARED BY JOEY M. TORAL
DOCUMENT NAME DESIGN STANDARDS MANUAL APPROVED BY JOEY M. TORAL
DOCUMENT SECTION TECHNICAL PROCEDURE SUBJECT BOILER CONTROLS
TITLE MOTORS AND MOTOR CONTROLS SPECIFICATIONS (COMPARTMENTALIZED)

3.3. MOTOR BRANCH CIRCUITS

3.3.1. Individual motor feeder lines should have a minimum ampacity of about 1.25 x FLC. Feeder
size selection should be based on current carrying capacities of 3C conductor cables @ 40°C
ambient air temperature with the following temperature ratings:

a.) 60°C for motors with FLC 100 amps or less.

b.) 75°C for motors with FLC above 100 amps.

3.3.2. Conductors with higher temperature ratings and current carrying capacities may be used
provided the vendor provides a full detail on the technical specifications of the cable and
guarantees its performance. Table No 5 shows recommended current carrying capacities of 3C-
conductor cables @ 40°C ambient air.

3.3.3. Conductors should be of insulated copper material with PVC outer covering (PVC/SWA/PVC)
and a minimum size of 2.5mm2 should be used on all feeder lines.

3.3.4. An inverse time moulded case circuit breaker and an overload relay should be used for motor
branch circuit protection.

3.3.5. To obtain the proper co-ordination between the thermal overload relay and the circuit breaker,
the latter should be rated at 1.75 x FLC. Setting can be increased up to 2.5 x FLC for nuisance
tripping.

3.3.6. Recommended maximum setting for thermal overload relays should be about 1.25 x FLC but it
depends on type of motor starting used and tripping characteristics of overload relays. For
motors with inherent thermal protectors the maximum overload relay setting are as
follows:

a.) 170 % for FLC < 9 Amperes

b.) 156 % for FLC < 20 Amperes
c.) 140 % for FLC > 20 Amperes

3.3.7. Motor branch circuits should have ammeters for motors 7.5 kW and above. Ammeters with
ratings above 75 Amperes should be of the current transformer type.

4. INSTRUMENT FEEDER LINES

4.1. A common feeder line should be provided for all instruments and controls inside the boiler control panel
and should be protected by a 15-ampere trip circuit breaker before branching out to different
instruments.

4.2. A fuse of 6A rating should protect each branch feeder line to an instrumentation or control circuit.
Minimum feeder line size should be 1.5mm2.

5. CONTROL PANEL

5.1. All motor starters and auxiliaries associated with the boiler shall be enclosed in a group motor control
center also known as the Boiler Control Panel.

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PAGE NUMBER Page 6
PREPARED BY JOEY M. TORAL
DOCUMENT NAME DESIGN STANDARDS MANUAL APPROVED BY JOEY M. TORAL
DOCUMENT SECTION TECHNICAL PROCEDURE SUBJECT BOILER CONTROLS
TITLE MOTORS AND MOTOR CONTROLS SPECIFICATIONS (COMPARTMENTALIZED)

5.2. Panel boards should be constructed for floor mounting, top or bottom cable entry and should be to
NEMA type 2 or IEC class IP11 or equivalent on non-hazardous and indoor locations; to NEMA type
3R or IEC class IP14 on non-hazardous outdoor locations. These standards shall apply as a minimum
requirement unless there is a specific project requirement.

5.3. Panel boards should be constructed of mild steel sheets and should be of the supporting frame
construction.

5.4. Panels should not be more than 2 meters high.

5.5. Each motor control should be housed in different compartments with bolted and gasketed hinged
doors. Doors should be designed to contain any fire hazard in the event of a high-energy short circuit.
All compartments shall be properly tagged with their associated equipment on the front door with white
on black labels.

5.6. Panel boards should be sized so that there is an ample space for wiring and installation of
components. Proper creepage distance should be observed over bare conductors.

5.7. All Panel steelwork shall be degreased and cleaned with De-oxidine (or power brush) before painting.
Painting shall comprise of two coats zinc chromate primer followed by two coats of semi-gloss grey
synthetic enamel.

5.8. Ventilating louvers should be provided for panels constructed to NEMA type 2 enclosures or
equivalent. Panels constructed to NEMA type 3R or equivalent shall be non-ventilated.

TABLE NUMBER 1 - CONTACTOR RATING FOR AC-3 DUTY, 440V

NEMA Size Rating(amps) NEMA Size Rating(amps)

00 9 3 90
0 12 4 125
01 16 05 190
1 25 5 250
1.5 32 6 400
02 38 7 740
2 45

TABLE NUMBER 2 – CONTACTOR SIZES FOR DIRECT-ON-LINE STARTING

MOTOR DATA DOL CONTACTOR MOTOR DATA DOL CONTACTOR

Kw FLC Amps Size kW FLC Amps Size
0.37 1.0 1.0 00 1.5 3.4 3.4 00
0.55 1.4 1.4 00 2.2 4.8 4.8 00
0.75 1.8 1.8 00 3.0 6.3 6.3 00

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PAGE NUMBER Page 7
PREPARED BY JOEY M. TORAL
DOCUMENT NAME DESIGN STANDARDS MANUAL APPROVED BY JOEY M. TORAL
DOCUMENT SECTION TECHNICAL PROCEDURE SUBJECT BOILER CONTROLS
TITLE MOTORS AND MOTOR CONTROLS SPECIFICATIONS (COMPARTMENTALIZED)

1.10 2.6 2.6 00 4.0 8.6 8.6 00

TABLE NUMBER 3 - CONTACTOR SIZES FOR STAR-DELTA STARTING

MOTOR DATA LINE CONTACTOR DELTA CONTACTOR STAR CONTACTOR

kW FLC Amps Size Amps Size Amps Size
5.5 11 6.27 00 6.27 00 3.63 00
7.5 14 7.98 00 7.98 00 4.62 00
11 21 11.97 0 11.97 0 6.93 00
15 27 15.39 01 15.39 01 8.91 00
18.5 34 19.38 1 19.38 1 11.22 0
22 40 22.8 1 22.8 1 13.2 01
30 52 29.64 1.5 29.64 1.5 17.16 1
37 65 37.05 02 37.05 02 21.45 1
45 77 43.89 2 43.89 2 25.41 1.5
55 96 54.72 3 54.72 3 31.68 1.5
75 124 70.68 3 70.68 3 40.92 2
90 156 88.92 3 88.92 3 51.48 3
110 180 102.6 4 102.6 4 59.4 3
132 210 119.7 4 119.7 4 69.3 3
150 240 136.8 05 136.8 05 79.2 3
185 295 168.15 05 168.15 05 97.35 4
200 318 181.26 05 181.26 05 104.94 4
225 358 204.06 5 204.06 5 118.14 4
Notes:
1.) Line contactor should be rated at 57% of AC-3 duty rating
2.) Delta contactor should be rated at 57% of AC-3 duty rating
3.) Star contactor should be rated at 33% of AC-3 duty rating

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PAGE NUMBER Page 8
PREPARED BY JOEY M. TORAL
DOCUMENT NAME DESIGN STANDARDS MANUAL APPROVED BY JOEY M. TORAL
DOCUMENT SECTION TECHNICAL PROCEDURE SUBJECT BOILER CONTROLS
TITLE MOTORS AND MOTOR CONTROLS SPECIFICATIONS (COMPARTMENTALIZED)

TABLE NUMBER 4 - CONTACTOR SIZES FOR AUTO-TRANSFORMER STARTING

MOTOR DATA LINE CONTACTOR TRANS. CONTACTOR STAR CONTACTOR

kW FLC Amps Size Amps Size Amps Size
5.5 11 11 0 7.04 00 2.75 00
7.5 14 14 01 8.96 00 3.5 00
11 21 21 1 13.44 01 5.25 00
15 27 27 1.5 17.28 1 6.75 00
18.5 34 34 02 21.76 1 8.5 00
22 40 40 2 25.6 1 10 0
30 52 52 3 33.28 1.5 13 01
37 65 65 3 41.6 2 16.25 01
45 77 77 3 49.28 3 19.25 1
55 96 96 4 61.44 3 24 1
75 124 124 4 79.36 3 31 1.5
90 156 156 05 99.84 4 39 02
110 180 180 05 115.2 4 45 2
132 210 210 5 134.4 05 52.5 3
150 240 240 5 153.6 05 60 3
185 295 295 6 188.8 05 73.75 3
200 318 318 6 203.52 05 79.5 3
225 358 358 6 229.12 5 89.5 3
Notes:
1.) Line contactor should be rated at 100% of AC-3 duty rating
2.) Delta contactor should be rated at 64% of AC-3 duty rating
3.) Star contactor should be rated at 25% of AC-3 duty rating
4.) All ratings are based on 70% voltage tap on transformer.

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PAGE NUMBER Page 9
PREPARED BY JOEY M. TORAL
DOCUMENT NAME DESIGN STANDARDS MANUAL APPROVED BY JOEY M. TORAL
DOCUMENT SECTION TECHNICAL PROCEDURE SUBJECT BOILER CONTROLS
TITLE MOTORS AND MOTOR CONTROLS SPECIFICATIONS (COMPARTMENTALIZED)

TABLE NUMBER 5 - AMPACITIES OF 3C CONDUCTOR CABLE, RATED AT 0 - 2000V, WITHIN AN

OVERALL COVERING, IN CONDUIT IN FREE AIR (BASED ON AMBIENT AIR TEMP OF 40°C)

Conductor Temperature Rating of Conductor

Size
(mm2)
60°C 75°C 90°C
2.5 18.0 23.0 26.5
4.0 23.5 30.0 34.0
6.0 30.0 37.5 42.0
10.0 38.5 49.5 57.5
16.0 51.0 65.5 76.5
25.0 68.0 88.0 102.0
35.0 83.0 107.5 126.0
50.0 105.0 136.0 158.0
70.0 128.5 166.5 194.0
95.0 155.0 201.0 235.0
120.0 181.0 233.5 273.0
150.0 207.0 267.0 312.0
185.0 235.0 304.0 356.0
240.0 271.0 351.0 411.0
300.0 303.0 393.0 462.0
400.0 348.0 454.0 534.0

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