Electricians will frequently need to size short circuit protection and overload protection
during their careers. This overview of motor calculations should help you understand
the requirements of the NEC® for sizing this protection and will also show you
examples of each calculation.. This module will also be helpful for examination
preparation purposes.
Ted “Smitty” Smith
Master Electrician
NEC® Instructor
The NEC and National Electrical Code are registered trademarks of the National Fire
Protection Association. See our main home page for contact information.
Motor
Calculations
It is important for all electricians to fully understand motor calculations.
This course will cover motor full load currents, branch circuit sizing, branch circuit
overload protection, feeder sizing, and feeder overcurrent protection sizing for single-
and three-phase, Alternating Current Motors of more than 1 horsepower.
There are six steps involved in calculating motors. It is a good idea to tab your book
and highlight the different steps so you can easily go through the steps.
Step 1 Single Phase – Find the FLC (full load current) – Table 430.148 single phase
Step 1 Three Phase – Find the FLC (full load current) – Table 430.150 three phase
Step 2 Sizing Overload Protection – Minimum = 430.32 (A) Maximum = 430.32 (C)
You will need the service factor and temperature rise information for this step.
Note: Use nameplate current rating when calculating overloads.
Step 3 Branch Circuit Conductor Sizing – 430.22 Single Motor: Calculate 125% of
FLC = Ampacity – Turn to 310.16 to find the wire size. Do not forget to apply the
requirements of 110.14 (C).
Step 4 Branch Circuit Overcurrent Protection Sizing – 430.52 Select type of motor
and type of overcurrent protection device from the chart and multiply values given by
the FLC of the motor. If the calculated value does not correspond to a standard fuse
or breaker size listed 240.6 then you are allowed to go up to the next higher size.
Step 5 Feeder Sizing – 430.24 Several motors or a motor with other load(s): Find
your largest motor and multiply the FLC of that motor by 125%. Add the FLC of all the
other loads connected to the same feeder. Turn to 310.16 to find the wire size.
Step 6 Feeder Overcurrent Protection Sizing – 430.62: Find the largest
overcurrent protection device for the branch circuits. Add the FLC of all the other
load(s) on the feeder. If the calculated value does not correspond to a standard fuse
or breaker size listed in 240.6 you must go to the next smaller size. Important: You
are not allowed to go up in size on feeders, only on branch circuits.
Detailed explanation of steps:
Step 1 – Find the “Full Load Current” of the motor. Find the phase of the motor, (this
will dictate which table you will go to for the FLC. If the motor is single phase, use
430.148. If the motor is three phase, use 430.150. Once you are at the appropriate
table. Find the voltage and horsepower of the motor and use the chart to find the
FLC. Write the FLC down, you will need it throughout each step except Step 2. If the
nameplate FLC rating is given, you will use it in Step 2.
Example: What is the FLC of a single phase, 2 HP, 115 volt motor?
Answer: T 430.148 FLC = 24 amps
Example: What is the FLC of a three phase, 5 HP, 230 volt motor?
Answer: T 430.150 FLC = 15.2 amps
Step 2 – 430.32(A) Calculate to find the minimum overload protection. You must
know the service factor and the temperature rise ratings of the motor.
The service factor rating is the amount of output the motor can develop without
causing harm to the motor. If a 5 HP motor has a service factor of 1.15 the motor can
produce an output of 5.75 HP without harming the motor. The service factor could be
seen as a safety measure, which would allow the motor to produce extra power if it
was needed.
The temperature rise is the difference of the motor winding temperature when running
at its full potential and the ambient temperature. If the temperature rise does not
exceed 40 C when running at its full potential, the motor will not be harmed. This is
also a safety margin.
Overloads protect the motor. This is why the service factor and the temperature rise is
important. Look at 430.32. If the service factor is not less than 1.15 or the
temperature is not more than 40 C then you are allowed to size the overload at 125%
of the FLC. If the motor has less than a 1.15 service factor or the temperature rise is
greater than 40 C then it falls into the “all other motors” category and you must size
the overload at 115%.
Maximum overload 430.32(C) – If the minimum overload is not of sufficient size to
start the motor or carry the load, the next higher size overload can be used, but you
can not exceed the percentages listed in 430.32 (C). You are allowed 140% of the
nameplate for motors with service factors of not less than 1.15 or a temperature rise of
not over 40 C. All other motors shall have a maximum overload protection of 130% of
the nameplate FLC.
!!! Always use the nameplate FLC if given when calculating OVERLOADS!!!
Example: What is the minimum overload for a 3hp, single phase, 115 volt motor with
a nameplate FLC of 32 amps, with a temperature rise of 40 C?
Answer: Nameplate rating = 32 amps x 125% (from table 430.32(A) = 40 minimum
overload
Example: What is maximum overload for the above motor?
Answer: Nameplate rating = 32 amps x 140% (from table 430.32(C)) = 44.8 maximum
overload.
Example: What if it asked for the maximum overload and did not give the nameplate
rating?
Answer: FLC from T430.148 = 34 amps x 140% = 47.6 maximum overload.
Always use nameplate FLC (430.6)
Example: What is the minimum overload for a 3hp, single phase, 115 volt motor with
a nameplate of 32 amps and a service factor of 1.10?
Answer: Nameplate rating = 32 amps x 115% (all other motors because the service
factor was less than 1.15) = 36.8 minimum overload.
Step 3 – 430.22 Calculating the minimum size branch circuit for a single motor is as
simple as multiplying the FLC by 125%. Conductors supplying a single motor shall
have an ampacity of not less than 125%. Use the FLC rating from Step 1.
Example: What is the minimum branch circuit ampacity for a 5hp, three phase, 230
volt motor using THW conductors?
Answer: FLC (T430.150) = 15.2 amps x 125% = 19 amps T310.16 = 14 AWG THW
Step 4 – Table 430.52 – Motors shall have a rating or setting of motor branch-circuit,
short circuit, and ground-fault protective devices capable of carrying the motors inrush
currents at startup. 430.52 is the maximum allowable ratings of these devices. You
will need to know the type of protective device and the type of motor. The protective
devices are listed in row at the tope of the chart.
If it is a single phase motor, you only have one column on the chart to find the
percentages of the FLC. If it is 3 phase (polyphase = more than one) you have
several choices. You will need to know whether it is a Wound Rotor, other than a
wound rotor, Squirrel Cage (Design E, or other than Design E, or a Synchronous type
motor. This will dictate which column you use to find the percentages of the FLC to
calculate maximum overcurrent protection.
Example: What is the maximum size inverse time breaker for a 5hp, three phase, 230
volt, wound rotor motor?
Answer: FLC = 15.2 amps x 50% (T430.52) = 22.8 go to 240-6. 22.8 is not a
standard size. You are allowed to go up to the next higher size for branch circuits.
Maximum size inverse time breaker = 25.
Step 5 – 430.24 When you have more than one motor or you have one motor and an
additional load the feeder conductors shall be equal to the sum of the FLC for all the
motors and all additional loads plus 25% of the FLC of the largest motor.
IMPORTANT: If you have an additional load which is not a motor, and the FLC of the
additional load is greater than the largest motor, you do not add 25% to the additional
load, you must add the 25% to the largest motor, regardless of the size of the
additional load. Turn to 310.16 to find the wire size.
Example – You have a motor with a FLC of 10 amps and a heat load of 15 amps on a
feeder.
Largest motor = 10 amps x 125% = 12.5 amps plus the additional heat load of 15
amps = 27.5 amps.
Even though the heat load FLC was greater than that of the motor, we still added the
25% to the largest motor!
Example: What is the minimum size THHN feeder allowed for 1 – 3hp, three phase,
208 volt motor and 1 – 2hp, single phase 208 volt motor?
Answer: 3hp motor – 10.6 amps – 2hp motor = 13.2 amps
Largest FLC motor = 13.2 amps x 125% = 16.5 amps plus smaller FLC motor 10.6
amps = 27.1
Go to 310.16 – THHN for 27.1 amps = 12 AWG Feeder Conductor
Step 6 - 430.62 A feeder supplying a specific fixed motor load(s) and consisting of
conductor sizes based on 430.24 shall be provided with a protective device having a
rating or setting not greater than the largest rating of the largest protective device for
any motor supplied by the feeder plus the sum of the FLC of the other motors in the
group.
You simply find the motor with the largest overcurrent protective device from Step 4
and add to the rating of that device the full load currents of all the other motors.
Example: What size feeder overcurrent protection using dual element fuses is
required for
1 – 3hp, three phase, 208 volt motor and
1 – 2hp, single phase, 208 volt motor?
Answer: Branch circuit OCP 3hp, 3 phase motor = 10.6 amps x 175% (T430.152) =
18.55 next higher size 20 amp
Branch circuit OCP 2hp, 1 phase motor = 13.2 amps x 175% (T430.152) = 23.10 next
higher size = 25 amp
For feeder overcurrent protection you add the branch circuit OCP for the largest motor
13.2 amps = 25 amp plus the FLC of the other motor (s).
25 amps (largest FLC motor) plus 10.6 amps (FLC of the small motor) = 35.6 amps.
Go to 240.6 to find standard fuse sizes. 35.6 is not a standard fuse size. You are not
allowed to go up to the next higher size for feeder overcurrent protection. You must
go down.
Maximum feeder overcurrent protection = 35 amp.
