Motor Calculations

TTo prevent a motor from burning up, you must provide a means of protecting it
from overcurrent (overload, short circuit, or ground fault). If you can remember
not to confuse motor protection with circuit protection, youll eliminate a major
point of confusion in motor calculations.

<b>Fig. 1.</b> Conductors for a single motor must have an ampacity of not less
than 125% of the motor full-load current rating.

Looking at Figure 430.1 in the NEC will help you keep this distinction clear. Notice that it
shows the requirements for motor overload protection in Part III and the requirements for
short-circuit and ground-fault protection in Parts IV and V.

Table or nameplate? To determine the minimum ampacity of the motor supply conductors,
you obviously need to know how much current the motor draws. But there are different types
of current in motor applications (see Motor Current Basics on page 80). Which do you use
full-load current (FLC) or full-load amperes (FLA) for your motor calculations?
The NEC does not permit the use of motor nameplate FLA to determine the conductor
ampacity; the branch-circuit short-circuit, and ground-fault overcurrent device size; or the
ampere rating of disconnecting switches [430.6(A)(1)]. But it must use the motor FLA to size
separate motor overload protection in accordance with Part III of Art. 430 [430.6(A)(2)].
Note the following exceptions:

If youre calculating separate motor overload protection for torque motors, use the locked
rotor current value on the nameplate [430.6(B)].

If a variable-frequency drive controls the motor, use the maximum operating current thats
marked on the nameplate (motor or control). If that value isnt on the nameplate, use 150% of
the values found in the NEC tables [430.6(C)].
<b>Fig. 3.</b> A branch-circuit short-circuit and ground-fault protective device
protects the motor against many things but not against overload.

High-torque motors (and those built to operate under 1,200 rpm) may have higher FLCs,
and the FLC of a multispeed motor varies with its speed. For such motors, use the nameplate
current ratings [430.6(A)(1)].

For a listed motor-operated appliance, use the FLC marked on the nameplate of the
appliance (rather than the horsepower rating) to determine the ampacity (or rating) of the
disconnecting means, branch-circuit conductors, controller, and branch-circuit short-circuit
and ground-fault protection [430.6(A)(1) Ex 3].

Overload protection. Overload protection must comply with 430 Part III. Size overload
protection devices based on the motor nameplate rating (this protects locked-rotor current
damage to motor windings) [430.31].

<b>Fig. 4.</b> Branch-circuit conductors are protected against overloads by the

overload device.

You can use a single overcurrent device, sized per 430.32 requirements, to protect a motor
from overload, short circuit, and ground faults.

Branch-circuit conductor size. Branch-circuit conductors to a single motor must have an

ampacity of not less than 125% of the FLC as listed in Tables 430.247 through 430.250
[430.6(A)(1), 430.22(A)].

When selecting motor current from one of these tables, note that the last sentence above each
table allows you to use the ampacity columns for a range of system voltages without any
adjustment. Select the conductor size from Table 310.16 according to the terminal
temperature rating (60C or 75C) of the equipment [110.14(C)].
THHN/THWN is a common conductor insulation type that can be used in a dry location at
the THHN 90C ampacity, or in a wet location at the 75C ampacity for the THWN insulation
type. Regardless of the conductor insulation type, size the conductor per 110.14(C).

In 110.14(C)(1)(a), we read that equipment terminals are rated 60C for equipment rated
100A or less (unless marked 75C). Today, most equipment terminals are rated at 75C. Look
for that specification, so you can use the 75C column if your conductors are also rated for
75C. If this is the case, you may save considerable money on your project. If you cant find
that specification, use the rules of 110.14(C).

Test your knowledge by answering this question: What size branch-circuit conductors are
required for a 7-hp, 3-phase, 230V motor (Fig. 1 on page 76)?

The motor FLC from Table 430.248 is 22A. The conductor is sized no less than 125% of
motor FLC: 22A 3 1.25 = 27.50A. As per Table 310.16, a 10 AWG conductor is rated 30A at
75C.

The minimum size conductor permitted for building wiring is 14 AWG [310.5]; however,
some local codes and many industrial facilities require branch-circuit conductors to be 12
AWG or larger.

Feeder conductor size. Perform feeder conductor size calculations the same way as for
branch circuits, but use the different ampacity rules provided in 430.24. Conductors that
supply several motors must have an ampacity of not less than:

(1) 125% of the highest rated motor FLC [430.17], plus

(2) The sum of the FLCs of the other motors (on the same line). Find the FLC in the NEC
Tables [430.6(A)(1)].

The highest rated motor is the motor with the highest FLC [430.17]. Determine the other
motors in the group value by balancing the motor FLCs on the feeder being sized, then
select the line that has the highest rated motor on it (Fig. 2 on page 78).

Branch-circuit short-circuit and ground-fault protection. Each motor branch circuit must
be protected against short circuit and ground faults by an overcurrent device sized no greater
than the percentages listed in Table 430.52. The motor branch-circuit short-circuit and
ground-fault protective device must be capable of carrying the motors starting current, and it
must comply with 430.52(B) and 430.52(C).

A branch-circuit short-circuit and ground-fault protective device protects the motor, the motor
control apparatus, and the conductors against short circuits or ground faults, but not against
overload [430.51] (Fig. 3 on page 78).
It bothers many electrical practitioners to see a 14 AWG conductor protected by a 30A circuit
breaker, but branch-circuit conductors are protected against overloads by the overload device
(Fig. 4). That device is sized between 115% and 125% of the motor nameplate current rating
[430.32]. See 240.4(G) for details.

Where the branch-circuit motor short-circuit and ground-fault protective device values
derived from Table 430.52 dont correspond with the standard overcurrent device ratings
listed in 240.6(A), you can use the next higher overcurrent device rating. The next size up
protection rule for branch circuits [430.52(C)(1) Ex 1] doesnt apply to the motor feeder
overcurrent device rating (Part II).

Keeping it straight. Articles 430 and 250 are the largest of the NEC Articles, and arguably the
most misapplied. Something else these two Articles have in common but not with the other
Articles is a Figure 1 you can use as a guide.

In the case of Art. 430, this figure is a simple representation of the motor system with the
correct Part of Art. 430 noted for each area of application. At the beginning of this article, we
said that using Figure 430.1 will help you to not confuse motor protection with circuit
protection when in actuality it can do much more. Spend some time working with it, and
youll see how useful it really is.

If you base each motor project on Figure 430.1, you will reduce if not eliminate Art.
430 application errors.

Sidebar: Other Functions of MV Power Cable Shielding

Nameplate rating. The full-load amperes (FLA) is the current the motor draws while
producing its rated horsepower load at its rated voltage.

NEC Tables. The full-load current (FLC) is the current value listed in Tables 450.247
through 450.250.
The actual current drawn by the motor depends upon the driven load and on the operating
voltage at the motor terminals. If the load increases, the current also increases. If the motor
operates at a voltage below its nameplate rating, the operating current will increase. Its
helpful to also understand:

Motor-starting current. When voltage is first applied to the field winding of an induction
motor, only the conductor resistance opposes the flow of current through the motor winding.
Because the conductor resistance is so low, the motor will have a very large inrush current
(see Figure above).

Motor-running current. Once the rotor begins turning, there is an increase in counter-
electromotive force that increases the impedance and thus reduces the current from the
starting amperage to running amperage.

Motor locked-rotor current. If the rotating part of the motor winding becomes jammed so
it cant rotate, no counter-electromotive force will be produced in the motor winding. This
results in a decrease in conductor impedance to the point that its effectively a short circuit.
Whats the result? The motor operates at locked-rotor current, often six times the full-load
ampere rating, depending on the motor Code Letter rating [430.7(B)]. This will cause the
motor winding to overheat and be destroyed if the current isnt quickly reduced or removed.