Motor Calculations, Part 1: Motors and branch conductors

Overcurrent and short-circuit protection are not the same for motors.

Mike Holt for EC&M Magazine

When providing overcurrent protection for most circuits, we use a circuit breaker that combines
overcurrent protection with short-circuit and ground fault protection. This is not usually the case for
motors. With rare exceptions, we accomplish motor overcurrent protection by separating the overload
protection devices from the short-circuit and ground-fault protection devices (see Figure 7-4).

Motor overload protection devices (i.e., heaters) protect the motor, the motor control equipment, and the
branch-circuit conductors from motor overload (and the resultant excessive heating) [430.31]. They do not
provide protection against short-circuits or ground-fault currents (see Figure 7-5). That is the job of the
branch and feeder breakers, which do not provide motor overload protection. This arrangement makes
motor calculations different from calculations used for other types of loads. Let's look at how to apply
Article 430, starting at the motor.

Overload protection

The motor overload devices are often integrated into the motor starter. But, you can use a separate
overload device such as a dual-element fuse (usually located near the motor starter, not the supply
breaker). If you use fuses, you must provide one for each ungrounded conductor [430.36 and 430.55].
Thus, a three-phase motor requires three fuses. Keep in mind that these devices are at the load end of
the branch circuit and they do not provide short-circuit and ground-fault protection.

Motors rated more than 1-hp (without integral thermal protection) and motors 1-hp or less (automatically
started) [430.32(C)], must have an overload device sized per the motor nameplate current rating
[430.6(A)]. You must size the overload devices no larger than the requirements of 430.32. Motors with a
nameplate service factor (S.F.) rating of 1.15 or more must have the overload protection device sized no
more than 125 percent of the motor nameplate current rating.

Let's look at Figure 7-7 and solve the following problem. Suppose you use a dual-element fuse for
overload protection. What size fuse do you need for a 5-hp, 230V, 1� motor (service factor 1.16), if the
motor nameplate current rating is 28A?

(a) 25A (b) 30A (c) 35A (d) 40A

Answer: (c) 35A

We size the overload protection per the motor nameplate current rating [430.6(A), 430.32(A)(1), and
430.55]. Thus, 28A x 1.25 = 35A [240.6(A)]

You also have to consider another factor: nameplate temperature rise. For motors with a nameplate
temperature rise rating not over 40�C, size the overload protection device no more than 125 percent of
the motor nameplate current rating.

Let's look at Figure 7-8 and solve the following problem. Again, you are using a dual-element fuse for the
overload protection. What size fuse do you need for a 50-hp, 460V, 3� motor that has a temperature rise
of 39�C and motor nameplate current rating of 60A (FLA)?

(a) 40A (b) 50A (c) 60A (d) 70A

Answer: (d) 70A

We size the overload protection per the motor nameplate current rating, not the motor Full Load Current
(FLC) rating. Thus, 60A x 1.25 = 75A, 70A [240.6(A) and 430.32(A)(1)].

Motors that do not have a service factor rating of 1.15 and up, or a temperature rise rating of 40�C and
less, must have the overload protection device sized at not more than 115 percent of the motor
nameplate ampere rating [430.37].

Sizing branch circuit conductors

Branch-circuit conductors to a single motor must have an ampacity of not less than 125 percent of the
motor's FLC as listed in Tables 430.147 through 430.150 [430.6(A)].

You must select the conductor size from Table 310.16 according to the terminal temperature rating (60�
or 75�C) of the equipment [110.14(C)]. See Figure 7-1. Let's review this, with a sample calculation.
What size THHN conductor do you need for a 2-hp, 230V, 1� motor (see Figure 7-2)?

(a) 14 AWG (b) 12 AWG

(c) 10 AWG (d) 8 AWG

o Answer: (a) 14 AWG

Let's walk through the solution:

 Conductor sized no less than 125% of motor FLC

 Table 430.148 shows the FLC of 2-hp, 230V 1� as 12A.
 12A x 1.25 = 15A
 Per Table 310.16, you need to use 14 AWG THHN rated 20A at 60�C

The minimum size conductor the NEC permits for building wiring is 14 AWG [310.5]. However, local
codes and many industrial facilities have requirements that 12 AWG be used as the smallest branch-
circuit wire. So, in this example you might need to use 12 AWG instead of 14 AWG.

Branch-circuit protection for short-circuits and ground-faults

Branch-circuit short-circuit and ground-fault protection devices protect the motor, the motor control
apparatus and the conductors against short circuits or ground faults. They do not protect against an
overload [430.51]. See Figure 7-6.

The short-circuit and ground-fault protection device required for motor circuits is not the type required for
personnel [210.8], feeders [215.9 and 240.13], services [230.95] or temporary wiring for receptacles
[527.6].

Per [430.52(C)], you must size the motor branch-circuit short-circuit and ground-fault protection (except
torque motors) so they are no greater than the percentages listed in Table 430.52.

When the short-circuit and ground-fault protection device value determined from Table 430.52 does not
correspond with the standard rating or setting of overcurrent protection devices as listed in 240.6(A), use
the next higher protection device size [430.52(C)(1) Ex. 1]. See Figure 7-9.

Did that statement stop you? Does it strike you as wrong? That's a common reaction, but remember,
motors are different. The motor overload protection devices (e.g., heaters or fuses) protect the motor and
other items from overload. The short-circuit and ground-fault protection does not need to perform this
function, thus an oversizing won't compromise protection. An undersizing will prevent the motor from
starting.

What's an easy way to determine what percentage from Table 430.52 you should use to size the motor
branch-circuit short-circuit ground-fault protection device? It's basically a two-step process:

Step 1: Locate the motor type on Table 430.52.

Step 2: Select the percentage from Table 430.52 according to the type of protection device such as
nontime delay (one-time) fuse, dual-element fuse or inverse-time circuit breaker. Don't forget, you may
need to use the next higher protection device size.

Let's see if you have this concept down, with a short quiz. Use Table 430.52 to look up the numbers. Of
the following statements, which one is true?

(a) The branch-circuit short-circuit protection (nontime delay fuse) for a 3-hp, 115V, 1� motor shall not
exceed 110A.

(b) The branch-circuit short-circuit protection (dual-element fuse) for a 5-hp, 230V, 1�, motor shall not
exceed 50A.

(c) The branch-circuit short-circuit protection (inverse-time breaker) for a 25-hp, 460V, 3� synchronous
motor shall not exceed 70A.

(d) All of these

Let's walk through each of these. We'll be referring to 430.53(C)(1) Ex. 1 and Table 430.52.

(a) Table 430.148. 34A x 3.00 = 102A. The next size up is 110A. So, this is true.

(b) Table 430.148. 28A x 1.75 = 49A. The next size up is 50A. So, this is also true.

(c) Table 430.150. 26A x 2.50 = 65A. The next size up is 70A. All three are true, so d is the correct
answer.

Let's review three very important principles:

1. You must size the conductors at 125% of the motor FLC [430.22(A)].

2. You must size the overloads from 115% to 125% of the motor nameplate current rating [430.32(A)(1)].

3. You must size the short-circuit ground-fault protection device from 150% to 300% of the motor FLC
[Table 430.52].

If you put all three of these together, you can see there is no relationship between the branch-circuit
conductor ampacity (125%) and the short-circuit ground-fault protection device (150% up to 300%).
See Figure 7-10.

Now, here's a final quiz to test your knowledge. Are any of the following statements is true for a 1-hp,
120V motor, nameplate current rating of 14A? Refer to Figure 7-11.

(a) The branch-circuit conductors can be 14 AWG THHN.

(b) Overload protection is from 16.1A.

(c) Short-circuit and ground-fault protection is permitted to be a 40A circuit breaker.

(d) All of these are true

Walking through each of these, we see:

(a) Conductor Size [430.22(A)]: 16A x 1.25 = 20A; Table 310.16 requires 14 AWG at 60�C.

(b) Overload Protection [430.32(A)(1)]: 14A (nameplate) x 1.15 = 16.1A

(c) Short-Circuit and Ground-Fault Protection [430.52(C)(1): 16A x 2.50 = 40A circuit breaker.

The 16A overload protection device protects the 14 AWG conductors from overcurrent, while the 40A
short-circuit protection device protects them from short circuits. This example explains the sometimes
confusing fact that, when doing motor calculations, you are calculating overcurrent and short-circuit
protection separately.

Motor calculations have long been a source of confusion and a point of error for many people. Now that
you understand what makes these calculations different, you should be able to do your motor calculations
correctly every time. In Part 2, we'll look at one more aspect of this: sizing motor feeders.