Electrical Construction & Maintenance Magazine

Motors and the NEC

Applying Article 430’s allowances for overcurrent protection
Mike Holt | Feb 13, 2013
http://www.ecmweb.com/code-basics/motors-and-nec?page=3

Article 430 provides the requirements for electric motors while Art. 440 offers amended and
additional requirements for hermetic motors, such as those used in air-conditioning and
refrigeration equipment. Motor applications are complex, because they’re inductive loads with
a high-current demand at startup. Because this inrush is typically six times the running
current, overcurrent protection for motor applications must differ from other equipment.

You might be uncomfortable with some of the Art. 430 allowances for overcurrent protection.
But once you understand how motor protection works, you’ll understand why these
allowances are not only safe, but also necessary.

Table FLC versus motor nameplate current rating (FLA). The motor full-load current ratings
listed in Tables 430.247, 430.248, and 430.250 are used to determine:

• Conductor ampacity [430.22].

• Branch circuit short circuit and ground fault overcurrent device size [430.52 and 430.62].

• Ampere rating of disconnecting switches [430.110].

The table selected for this purpose depends on the type of motor being used. The correct full-
load current (FLC) is selected from:

• Table 430.247 direct current motors

• Table 430.248 single-phase motors

• Table 430.250 3-phase motors

However, for some specific types of motors, the actual nameplate full-load amperes (FLA)
must be used instead of the FLC (see FLA vs. FLC).

Use the nameplate FLA when sizing conductors, branch circuit short circuit and ground fault
protection, and disconnecting switches for:

• Motors built to operate under 1,200 rpm.

• Motors that have high torques (and thus higher FLCs).

• Multispeed motors (FLC varies with speed).

• A listed motor-operated appliance.

Also, use the nameplate FLA for sizing of separate motor overload protection [430.6(A)(2)].

Conductor size

If for a single motor, size conductors at least 125% of the motor FLC rating as listed in Table
430.247 [Direct-Current Motors], Table 430.248 [Single-Phase Motors], or Table 430.250
[Three-Phase Motors] (430.22). Let’s review a sample problem for clarity.

Fig. 1. Conductors for a single motor must have an ampacity of not less than 125% of the
motor full-load current rating.
 What size 75°C branch circuit conductor is required for a 7½-hp, 230V, 3-phase motor, as
shown in Fig. 1?

Motor FLC = 22A [Table 430.250]

Conductor’s size = 22A × 1.25 = 27.50A

A check of Table 310.15(B)(16) reveals that a 10 AWG conductor is rated 30A at 75°C.

Note: The branch circuit short circuit and ground fault protection device using an inverse time
breaker is sized at 60A, according to 430.52(C)(1) Ex 1:

Circuit protection = 22A × 2.50 = 55A, next size up 60A [240.6(A)]

Circuit conductors that supply several motors must not be smaller than the minimum
ampacity found by adding [430.24]:

• 125% of the FLC of the highest rated motor.

• The FLCs of other motors

For this purpose, the highest rated motor is the one with the highest FLC [430.17]. Let’s
review another example for clarity.

What size 75°C feeder conductor is required for two 7½-hp, 230V, 3-phase motors if the
terminals are rated for 75°C?

Motor FLC = 22A [Table 430.250]

Motor feeder conductor = (22A × 1.25) + 22A = 49.50A

A check of Table 310.15(B)(16) reveals that an 8 AWG conductor is rated 50A at 75°C.

Note: The feeder overcurrent device (inverse time circuit breaker) must comply with 430.62
as follows:
 Step 1: Determine the largest branch circuit overcurrent device rating [240.6(A) and
430.52(C)(1) Ex 1]: 22A × 2.50 = 55A, next size up is 60A

Step 2: Size the feeder overcurrent device in accordance with 240.6(A) and 430.62: 60A +
22A = 82A, next size down is 80A

Note: The “next-size-up protection” rule for branch circuits [430.52(C)(1) Ex 1] doesn’t apply
to motor feeder short circuit and ground fault protection device sizing.

Taps

For motor circuit conductors tapped from a feeder [430.28], determine the ampacity per
430.22. The tap conductors must terminate in a branch circuit short circuit and ground fault
protection device sized per 430.52.

Motor feeder tap conductors must have an ampacity that’s at least:

• One-tenth the rating of the feeder protection device, if not over 10 ft.

• One-third the ampacity of the feeder conductor, if over 10 ft but not over 25 ft.

• As large as the feeder conductor ampacity.

Overload protection

A fault, such as a short circuit or ground fault, isn’t an overload [Art. 100]. Overload is the
operation of equipment in excess of its current rating — or where current is in excess of the
conductor ampacity.

Sustained overload will dangerously overheat the equipment or even destroy it. So we want to
protect motors, motor control equipment, and motor branch circuit conductors against
excessive heating from overload. You must install an overload protection device for each
ungrounded conductor [430.37].
Motor circuit overload protection requirements are in Art. 430, Part III. These are for
overload and failure-to-start protection only. Overload protection isn’t required if it might
introduce additional or increased hazards, as in the case of fire pumps (see 695.7).

Because of the difference between starting and running current (see Starting, Running,
and Locked), overcurrent protection for motors differs from that of other circuits. Generally,
the motor overload device is separate from the short circuit and ground fault protection device
(Art. 430 Part IV) [Fig. 2].

Fig. 2. Overcurrent is any current in excess of the equipment rating. It can be caused by
overload, short circuit, or ground fault [Art. 100].

Overload devices come in many configurations. They can be conventional “heaters” or

electronic. You can use a fuse sized per 430.32. If you use fuses for overload protection,
provide one for each ungrounded conductor [430.36].

You can use a single overcurrent device to protect a motor against overload, short circuit, and
ground fault [430.55]. However, you must size it to the overload requirements in 430.32.
 Continuous duty

Motors rated more than 1 hp, used in a continuous-duty application without integral thermal
protection, must have an overload device sized to open at no more than 115% of the motor
nameplate FLC rating [430.32(A)(1)]. But size the overload device no more than 125% of the
nameplate FLC if:

• The nameplate service factor (SF) is 1.15 or more.

• The nameplate temperature rise is 40°C or less.

Branch circuit short circuit and ground fault protection

A branch circuit short circuit and ground fault protective device protects the motor, the motor
control equipment, and the conductors against short circuits or ground faults. It does not
protect against overload [430.51] (Fig. 3).

Fig. 3. A branch circuit short circuit and ground fault protective device does not protect
against overload.

The motor branch circuit short circuit and ground fault protective device must be capable of
carrying the motor’s starting current [430.52(B)]. Install a branch circuit short circuit and
ground fault protective device on each motor circuit, and ensure that it is sized no greater
than the percentages listed in Table 430.52. Let’s take a look at another example problem.
What size 75°C conductor and inverse time circuit breaker are required for a 2-hp, 230V,
single-phase motor?

Step 1: Determine the branch circuit conductor [Table 310.15(B)(16), 430.22, and Table
430.248]: 12A × 1.25 = 15A

As per Table 310.15(B)(16), a 14 AWG conductor is rated 20A at 75°C.

Step 2: Determine the branch circuit protection [240.6(A), 430.52(C)(1), and Table
430.248]: 12A × 2.50 = 30A

Overcurrent protection for motors is different than protection for other types of electrical
loads, and the values you come up with might not seem right based on your experience with
other types of applications. Protecting a 14 AWG conductor with a 30A circuit breaker, for
example, just looks wrong. But keep in mind that motor branch circuit conductors are
protected against overloads by the overload device. That device is sized between 115% and
125% of the motor nameplate current rating [430.32].

The small conductor rule contained in 240.4(D), which limits 15A protection for 14 AWG,
doesn’t apply to motor circuit protection. See 240.4(D) and 240.4(G).

Feeder protection

You need to protect motor feeder conductors against short circuits and ground faults. But how
do you size the protective device to handle this job? First, determine which motor on the
feeder has the largest rated branch circuit short circuit and ground fault protective device.
Next, add up the FLCs of the other motors in the group. Finally, add that sum to the device
rating from the first step [430.62(A)].

The “next-size-up protection” rule for branch circuits [430.52(C)(1) Ex 1] doesn’t apply to a
motor feeder protection device rating. Thus, you may need to round down to the protection
device that “does not exceed” that calculated value. An example problem helps illustrate this.
What size feeder protection (inverse time breakers with 75°C terminals) and 75°C conductors
do you need for the following two motors (Fig. 4)?

Fig. 4. The feeder protection device in this example should not be larger than 84A (70A +
14A).

Motor 1 — 20 hp, 460V, 3-phase = 27A FLC [Table 430.250]

Motor 2 — 10 hp, 460V, 3-phase = 14A FLC

Here’s the solution:

Step 1: Determine the feeder conductor size [430.24]: (27A × 1.25) + 14A = 48A
8 AWG rated 50A at 75°C [110.14(C)(1) and Table 310.15(B)(16)]

Step 2: Feeder protection [430.62(A)] isn’t greater than the largest branch circuit ground fault
and short circuit protective device plus the other motor FLC.

Step 3: Determine the largest branch circuit ground fault and short circuit protective device
[430.52(C)(1) Ex]: 20 hp motor = 27A × 2.50 = 68, next size up = 70A

10 hp motor = 14A × 2.50 = 35A

 Step 4: Determine the feeder protection: not more than 70A + 14A, = 84A.

Next size down = 80A [240.6(A)]

Therefore, for this specific arrangement, you would use 8 AWG conductor and an 80A
breaker.

Article 430 road map. Compared to other NEC Articles, Art. 430 is long and complex. But now
that you have a good overview of its requirements, you can combine this knowledge with the
“map” shown in Figure 430.1 to boost your calculation efficiency and accuracy.

SIDEBAR 1: Starting, Running, and Locked

A motor draws significantly more current when starting than when running. It draws even
more in a locked-rotor condition.

• 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 winding. Because
conductor resistance is very low, the motor has a large inrush current.

• Running current. Once the rotor reaches rated speed, the starting current reduces to running
current due to the counter-electromotive force (CEMF).

• Locked-rotor current (LRC). If the rotating part of the motor winding (armature) can’t rotate
(for instance, due to a jam), then the winding produces no CEMF. Consequently, conductor
impedance decreases until it’s effectively a short circuit. The motor operates at LRC, often six
times the full-load ampere rating, depending on the motor code letter rating [430.7(B)]. The
resulting overheating of the motor winding will destroy the winding if the current isn’t quickly
reduced or removed.

FPN – no in magazine
Counter-electromotive force
https://en.wikipedia.org/wiki/Counter-electromotive_force

Counter-electromotive force (abbreviated counter EMF or simply CEMF),[1] also known as back
electromotive force (or back EMF), is the electromotive force or "voltage" that opposes the change
in current which induced it. CEMF is the EMF caused by magnetic induction (see Faraday's law of
induction, electromagnetic induction, Lenz's Law).
 For example, the voltage appearing across an inductor or "coil" is due to a change in current which
causes a change in the magnetic field within the coil, and therefore the self-induced voltage.[1][2]
The polarity of the voltage at every moment opposes that of the change in applied voltage to keep
the current constant.[1][3]

The term back electromotive force is also commonly used to refer to the voltage that occurs in electric
motors where there is relative motion between the armature and the magnetic field produced by the
motor's field coils, thus also acting as a generator while running as a motor. This effect is not due to
the motor's inductance but a separate phenomenon.

This voltage is in series with and opposes the original applied voltage and is called "back-
electromotive force" (by Lenz's law). With a lower overall voltage across motor's internal resistance
as the motor turns faster, the current flowing into the motor decreases.[4] One practical application
of this phenomenon is to indirectly measure motor speed and position, as the back-EMF is
proportional to the rotational speed of the armature.[5]

In motor control and robotics, the term "Back-EMF" often refers most specifically to actually using
the voltage generated by a spinning motor to infer the speed of the motor's rotation for use in better
controlling the motor in specific ways.[6]

To observe the effect of Back-EMF of a motor, one can perform this simple exercise. With an
incandescent light on, cause a large motor such as a drill press, saw, air conditioner compressor, or
vacuum cleaner to start. The light may dim briefly as the motor starts. When the armature is not
turning (called locked rotor) there is no Back-EMF and the motor's current draw is quite high. If the
motor's starting current is high enough it will pull the line voltage down enough to notice the dimming
of the light.

SIDEBAR 2: FLA Vs. FLC

The nameplate full-load ampere (FLA) rating is the current the motor draws while producing
its rated horsepower load at its rated voltage, based on its rated efficiency and power factor.
The current the motor actually draws depends on the actual voltage at the motor terminals
and the load the motor is trying to drive. The current increases if the load increases or if the
voltage decreases.

Caution: To prevent damage to motor windings from excessive heat (caused by excessive
current), never load a motor above its horsepower rating, and be sure the voltage source
matches the motor’s voltage rating.
The full-load current (FLC) tables are found at the end of Art. 430. In general terms, the
permanent wiring installed for motor circuits is sized based on these tables, which are
intended to be large enough for any motor design of a particular horsepower rating.