Article 240: Overcurrent Protection

Article 240 provides the requirements for selecting and installing overcurrent protection devices
(OCPDs). Depending on your application, other Articles may apply (see Other Articles below).

An overcurrent exists when current exceeds the rating of conductors or equipment. It can result from
overload, short circuit, or ground fault.

 An overload is a condition in which equipment or conductors carry current exceeding their rated
ampacity. An example is plugging two 12.5A (1,500W) hair dryers into a 20A branch circuit.
 A short circuit is the unintentional electrical connection between any two normally current-carrying
conductors of a circuit (line-to-line or line-to-neutral).
 A ground fault is an unintentional, electrically conducting connection between an ungrounded
conductor of a circuit and the equipment grounding conductor, metallic enclosures, metallic raceways,
metallic equipment, or earth. During a ground fault, dangerous voltages and abnormally large currents
exist.

Circuits or equipment?

OCPDs protect circuits and equipment, but they protect circuits in one way and equipment in another.

An OCPD protects a circuit by opening when current reaches a value that would cause an excessive
temperature rise in the conductors. Using a water analogy, current rises like water in a tank — at a
certain level, the OCPD shuts off the faucet. Think in terms of normal operating conditions that just get
too far out of normal range. The interrupting rating must be sufficient for the maximum possible fault
current available on the line-side terminals of the equipment [110.9]. You'll find the standard ratings
for fuses and fixed-trip circuit breakers in 240.6.
 An OCPD protects equipment by opening when it detects a short circuit or ground fault. Every piece of
electrical equipment must have a short-circuit current rating that permits the OCPDs (for that
equipment) to clear short circuits or ground faults without extensive damage to the electrical
components of the circuit [110.10]. Short circuits and faults aren't normal operating conditions. Thus,
the OCPDs for equipment have different characteristics than OCPDs for conductors.

Circuit protection

OCPDs come in standard sizes, which are listed in 240.6. When you size conductor OCPDs, you're
trying to determine which of these standard sizes to use. Begin this sizing by determining the
conductor ampacity and then making ampacity adjustments specified in 310.15 [240.4].

OCPD application will vary under the following circumstances:

Power loss hazard

Conductor overload protection is not required where circuit interruption would create a hazard (e.g., a
fire pump). Short-circuit protection is still required.

Not over 800A

You can use the next higher standard rating overcurrent device (above the ampacity of the ungrounded
conductors being protected) if all of the following conditions are met:

 The conductors do not supply multi-outlet receptacle branch circuits.

 The ampacity of a conductor after ampacity adjustment and/or correction doesn't correspond to the
standard rating of a fuse or circuit breaker in 240.6(A).
 The protection device rating doesn't exceed 800A.

Fig. 1. If the circuit’s overcurrent protection device exceeds 800A, the conductor
ampacity after ampacity adjustment must have a rating not less than the overcurrent
device rating.

For example, a 400A OCPD can protect 500kcmil conductors, where each conductor has an ampacity
of 380A at 75°C per Table 310.16. This “next-size-up” rule doesn't apply to feeder tap conductors
[240.21(B)] or secondary transformer conductors [240.21(C)].

Over 800A
 If the OCPD exceeds 800A, the conductor ampacity (after ampacity adjustment and/or correction)
must have a rating not less than the rating of the OCPD. For example, a 1,200A OCPD can protect three
sets of 600kcmil conductors per phase, where each conductor has an ampacity of 420A at 75°C per
Table 310.16 (Fig. 1).

Small conductors

Unless specifically permitted in 240.4(E) or (G), overcurrent protection must not exceed (after
ampacity adjustment and/or correction):

 15A for 14 AWG copper.

 15A for 12 AWG aluminum.
 20A for 12 AWG copper.
 25A for 10 AWG aluminum.
 30A for 10 AWG copper.

Supplementary OCPDs

Fig. 2. A supplementary overcurrent protection device provides limited overcurrent

protection in specific applications such as with luminaires and appliances.

A “supplementary OCPD” provides limited overcurrent protection for specific applications and
utilization equipment (Fig. 2). It's usually an internal fuse. Supplementary OCPDs are often used in
luminaires, appliances, and equipment for internal circuits and components.

You cannot use a supplementary OCPD as the required branch-circuit OCPD [240.10]. A
supplementary OCPD doesn't have to be readily accessible [240.24(A)(2)].

Location in circuit

Install OCPDs at the point where the branch or feeder conductors receive their power. Exceptions exist
in 240.21 (A) through (G). Here's a summary of each of these, but be sure to read the details if the
exception applies to your situation.

(A) Branch circuits meeting 210.19 requirements are exempted from 240.21 location requirements.
Examples include multiwire and range circuits.

(B) You can't make a tap from a tap.

 (C) The OCPDs for the primary side of a transformer provide protection for the secondary side, if
certain conditions are met.

(D) Service conductors are covered by 230.91.

(E) Busway taps are covered by 368.17.

(F) For motors, apply 430.28 and 430.53.

(G) For generators, apply 445.12 and 445.13.

Location of OCPDs on premise

Circuit breakers and fuses must be readily accessible [240.24]. “Readily accessible” means located so a
person can reach it quickly without having to climb over (or remove) obstacles or use a portable ladder.
This rule does not prohibit the locking of panel doors or the placing of a padlock on a circuit breaker to
restrict access [110.26].

Install OCPD enclosures such that the center of the grip of the operating handle, when in its highest
position, isn't more than 6 feet 7 inches above the floor or working platform. Four exceptions exist for
this rule:

 Busways as provided in 368.17(C).

 Supplementary OCPDs [240.10].
 OCPDs as described in 225.40 and 230.92.
 OCPDs located next to equipment can be mounted above 6 feet 7 inches, if accessible by portable
means [404.8(A) Exception No. 2] (Fig. 3).

Fig. 3. Overcurrent protection devices located next to equipment can be mounted

above 6 feet 7 inches, if accessible by portable means.

OCPDs must not be exposed to physical damage. Electrical equipment must be suitable for the
environment. Give consideration to the presence of corrosives, which may deteriorate conductors or
equipment [110.11].

Don't locate OCPDs near easily ignitable material or in locations such as clothes closets. Don't locate
them in bathrooms of dwelling units or guest rooms (or guest suites) of hotels or motels. This rule also
applies to the service disconnecting means, even in commercial or industrial facilities [230.70(A)(2)].
Enclosures

Enclosures containing OCPDs must be mounted in a vertical position unless this is impractical
[240.33]. Circuit breaker enclosures can be horizontal if the circuit breaker is installed per 240.81.

Fig. 4. Enclosures for overcurrent devices must be mounted in a vertical position,

unless this is impractical.

The requirements of 240.81 specify that where circuit breaker handles are operated vertically, the “up”
position of the handle must be in the “on” position. Therefore, an enclosure that contains one circuit
breaker can be mounted horizontally, but an enclosure that contains a panelboard or load center with
multiple circuit breakers on opposite sides of each other would have to be mounted vertically (Fig. 4).

Also note that these enclosures are designed for left-hand operation, under the assumption that the
operator is right-handed. The intended result is that the operator is standing to one side of the
enclosure, rather than in front of it (and in the blast path) when operating it. Allow space for this when
installing the enclosure.

Circuit breakers

Circuit breakers must be capable of being opened and closed by hand [240.80]. Non-manual means of
operating a circuit breaker, such as electrical shunt trip or pneumatic operation, are permitted only if
the circuit breaker can also be manually operated.

Circuit breakers used to switch 120V or 277V fluorescent lighting circuits must be listed and marked
SWD or HID. Circuit breakers used to switch high-intensity discharge lighting circuits must be listed
and marked HID.

UL 489, Standard for Molded Case Circuit Breakers, permits “HID” breakers to be rated up to 50A, but
an “SWD” breaker may be rated only to 20A. The tests for “HID” breakers include an endurance test at
75% power factor, but “SWD” breakers are endurance-tested at 100% power factor. The contacts and
the spring of an “HID” breaker are constructed of a heavy-duty material designed to dissipate the
increased heat caused by the greater current flow in the circuit that occurs because the “HID”
luminaire takes a minute or two to ignite the lamp.
 Before you start any OCPD calculations, first determine if you're trying to protect circuits or
equipment. Next, determine if any other Articles apply for your application. Then, you can plug in the
numbers and select the correct OCPD.

Sidebar: Other Articles

Your application may fall under one of these other Articles:

 Air-conditioning and refrigeration equipment [440.22]

 Appliances [Art. 422]
 Audio circuits [640.9]
 Branch circuits [210.20]
 Class 1, 2, and 3 circuits [Art. 725]
 Feeder conductors [215.3]
 Flexible cords [240.5(B)(1)]
 Fire alarms [Art. 760]
 Fire pumps [Art. 695]
 Fixed electric space-heating equipment [424.3(B)]
 Fixture wire [240.5(B)(2)]
 Panelboards [408.36(A)]
 Service conductors [230.90(A)]
 Transformers [450.3]

the difference between overload and overcurrent

protective

QUESTION:
What is the difference between overcurrent protection and overload
protection?

ANSWER:
Overcurrent protection is protection against excessive currents or
current beyond the acceptable current rating of equipment. It
generally operates instantly. Short circuit is a type of overcurrent.
Magnetic circuit breakers, fuses and overcurrent relays are
commonly used to provide overcurrent protection.
Overload protection is a protection against a running overcurrent
that would cause overheating of the protected equipment. Hence, an
overload is also type of overcurrent. Overload protection typically
operates on an inverse time curve where the tripping time becomes
less as the current increases. Overload relays as well as “slow
blow” fuses are commonly used to provide overload protection.

Some devices provide both overcurrent and overload protection. A

thermal-magnetic circuit breaker has both thermal (overload) and
magnetic (overcurrent) elements. Both elements operate as
described above. Likewise the dual element fuse has both
instantaneous and inverse time characteristics in the same fuse
providing both overcurrent and overload protection.

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Voltage Surges

Voltage Surges: Causes and Control

Electrical devices are designed to handle specific voltages. Unfortunately, in cases where devices are subject to
higher voltages than they are designed for, damage can occur. Generally speaking the greater these voltages are,
and the longer the period over which they are experienced, the greater the damage will likely be.
Sudden, severe voltage surges like those experienced as a result of lightning can cause almost immediate and
total failure of electronic devices, requiring expensive repair work or replacement. However even small voltage
surges are capable of causing damage over an extended period of time.
One common example of the damage that can be caused by excessive voltage involves the rapid heating – and
subsequent cooling – of electrical wiring. Over time this repeated overheating can lead to “electronic rust” and
eventual failure of devices.
It is also important to note that minor voltage surges can frequently go unnoticed; where these do not cause
immediate failure, the owner may not be aware that their computer or other electronic device is being degraded
on a consistent basis. As a result, power surges can be seen as one of the “silent killers” of electronic devices.
The damage caused by voltage surges can be serious enough in the home; however when the effects are felt in a
wider industrial scale they can even more disastrous, affecting expensive machinery and even whole sections of
the power grid. Unsurprisingly, for such a disastrous process, it is wise to use some form of surge protection, so
as to mitigate the risks that power surges can cause.
Voltage Surges vs Voltage Spikes

In terms of short-term increases in voltage being supplied to a system we can think of both “voltage surges” and
“voltage spikes”. While these may at first value sound like identical phenomena they are in fact considered rather
different, on account of their longevity.
A sudden rise in voltage lasting three nanoseconds or more is generally classed as a “voltage surge” while a spike
more typically refers to shorter-lived increases in power.
As a result while both phenomena can be disruptive in a system and cause considerable damage, generally
speaking voltage surges are considered more damaging. This is due to the longer period of time in which the
electric circuit must deal with the excessive power.
What Causes Voltage Surges

Engineers generally recognize two causes of voltage surges. These are classified as “internal” sources as they
derive from changes within the system itself or “external” causes which come from outside the system currently
being affected by the surge.
Internal Sources – Voltage Surges

Many electrical systems operate by either turning on and off power or by increasing and decreasing the flow of
power. Think of thermostats or dimmer switches as examples of circuits designed to increase/decrease electrical
load. Alternatively, think of the fan in your computer or the compressor on your fridge repeatedly turning on and
off, consequently affecting the power available in your home.
However this is far from the only internal source of power surges. A second source of power surges involves
“magnetic coupling”. When electricity flows through a circuit, a magnetic field is created. In some circumstances
this field can affect nearby wires, inducing a voltage in them and so leading to an unexpected power surge.
Lastly static electricity can build up within a system over time which, when discharged, causes a significant short
term voltage surge.
External Sources – Voltage Surges

The different external sources of voltage surges can differ by region. In developing countries a common source
of power surges arises from differences in how power in the national grid is used. In the evening, for example, as
the nation returns home and switches on their TVs, air conditioning and so on can drain power from the grid. As
these are turned off en masse in readiness for bed power surges can result.
Elsewhere in the world arguably the most common external cause of voltage surges come from lightning. While
lightning may actually strike the circuit itself causing a power surge, a far more common cause of voltage surges
is lightning hitting circuits nearby. In such situations overhead power cables may find themselves in the receiving
end of a lightning strike – leading to a short-term spike in electrical activity for the surrounding properties.
Voltage Surge Protectors

There can be few engineers or electricians have not seen the devastating impact that voltage surges can cause. It
should therefore come as no surprise that protecting systems from voltage surges should be considered of
primary importance. This is especially so in situations where voltage surges are highly likely, or where the
effects of an uncontrolled voltage surge could cause widespread, or expensive, damage.
To this end a range of voltage surge protectors are now available. In essence these devices are designed as “gate
keepers” for a system, helping to monitor the electrical charge entering the system. In cases where surges or
spikes are experienced the excess voltage is then removed from the system, such as through earthed lead.
Clearly when choosing a surge suppressor there are a number of factors that should be considered. On the one
hand, surge protectors are manufactured to deal with a range of voltages around the anticipated mean. The
broader this range is, the more protection will be offered to the system. Consequently selecting protection
devices with a wide functional range is highly recommended.
A second consideration is the speed of operation; how quickly can a voltage surge protector eliminate unwanted
excess current, and as a result how long will the system experience a sub-optimal load? The greater speed at
which your protector can respond will minimize the risk of damage such as burnout occurring.
Lastly consider whether the device you are considering includes moving parts. While many of the newer models
on the market are electronic-only designs, some manufacturers still produce surge protectors with moving parts
which can, as a result, lead to mechanical failure.
Generally speaking electronic-only surge suppressors suffer far fewer mechanical problems and so offer higher
levels of reliability. This eliminates the need (and cost) of regular maintenance and ensures fewer complications
from negative environmental conditions such a dusty or humid atmospheres.

ATS
A transfer switch is an electrical switch that switches a load between two sources. ... An Automatic
TransferSwitch (ATS) is often installed where a backup generator is located, so that the generator
may provide temporary electrical power if the utility source fails

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