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What should be done if the overload relay designated for a motor is not sufficient to start or carry the load?

  1. Reduce the load

  2. Decrease the motor size

  3. Use the same relay

  4. Choose a higher size overload relay

The correct answer is: Choose a higher size overload relay

When an overload relay designated for a motor is found to be insufficient to start or carry the load, selecting a higher size overload relay is the appropriate course of action. Overload relays are critical components designed to protect motors from overheating due to excessive current draw. Each motor has specific ratings regarding the current it can handle when running under normal load conditions. When the overload relay is undersized, it can either trip unnecessarily, causing the motor to stop prematurely, or fail to protect the motor adequately, leading to potential damage. Choosing a higher size overload relay ensures that it can handle the initial surge of current during startup as well as the steady-state running current when the motor is under load. This adjustment not only provides better protection for the motor but also allows it to operate efficiently without the risk of nuisance tripping. In certain applications, motors can have higher starting currents that last only a short duration, and an appropriately rated relay accommodates this without compromising safety. Additionally, while options like reducing the load or decreasing the motor size may help manage the situation, they do not address the protection needs of the system responsible for safeguarding equipment. Using the same relay that has proven to be insufficient would also likely lead to repeated issues. Hence, opting for a higher capacity overload