codeissues

By James Stallcup Sr., NEC/OSHA Consultant

NOTE: CONTROLLER MUST BE EQUAL TO THE

Key Elements For Designing
H P OF THE MOTOR THAT IT CONTROLS.
OCPD
• 430.52(C)(1)
• TABLE 430.52 CONTROLLER
A Reliable Motor Circuit – PART 1
• 430.83
FUSES TD DISCONNECTING • 50 HP
• 430.32(A)(1) MEANS OL’S In the previous edition of necdigest®, the elements
• 430.57 • 430.110(A) • 430.32(A)(1)
• 430.55 OL CHART necessary for designing the conductors and overcurrent
• H1051
BASED ON protective devices for a reliable motor branch circuit
62 A NPC were discussed. This article will discuss the remaining key
MBJ
GES elements that are necessary.
GEC
SIZING PROCEDURE SIZING THE RUNNING OVERLOAD PROTECTION
SERVICE FACTOR OF 1.15 OR GREATER 50 HP MOTOR FOR MOTORS – 430.32(A)(1)
• FLA x 125% = OL RATING 3Ø, 46O V
TEMPERATURE RISE OF NOT OVER 40°C DES. B; NP-62 A; Devices such as thermal protectors, thermal relays, or
• FLA x 125% = OL RATING TR-40°C; SF 1.15
ALL OTHER MOTORS Fusetrons may be installed to provide running overload
• FLA x 115% = OL RATING MOTOR NAMEPLATE protection for motors rated more than 1 horsepower.
The service factor or temperature rise of the motor shall
FINDING MOTOR OVERLOAD PROTECTION
be used when sizing and installing the running overload
Sizing OL’s using fuses
protection for motors. The running overload protection
Step 1: Finding FLA
430.6(A)(2) is set to open at 115 percent or 125 percent of the
Nameplate = 62 A
motor's full load current. Under certain conditions of
Step 2: Finding percentage
430.32(A)(1) use, the running overload protection shall be set at
SF = 125% 115 percent when the motor is not marked with a service
TR = 125%
factor or temperature rise. Time delay fuses selected and
Step 3: CalculatingFLA
430.32(A)(1) sized at these percentages provide overload or back-up
62 A x 125% = 77.5 A
overload protection.
Step 4: Selecting TD fuses
430.32(A)(1); 240.6(A)
77.5 A requires 70 A MINIMUM SIZE OVERLOAD PROTECTION
Solution: The size time delay fuses are 70 amps. 430.32(A)(1)
Note: 80 amp TDF’s provide backup OL protection. The amperage for full load current ratings listed in
Tables 430.247 through 430.250 shall not be used when
Sizing OL’s in controller
sizing the running overload protection. The full load
Step 1: Finding FLA
430.6(A)(2); 430.32(A)(1) current listed on the motor's nameplate shall be used to
62 A x 125% = 77.5 A
size the running overload protection.
Solution: The size overloads are selected from
a manufacturer's chart based on 62
The running overload protection shall be selected and
amps. rated no larger than the following minimum percentages
ILLUSTRATIONS COURTESY OF GRAYBOY, INC.

Note: The OL units are already computed at
77.5 amps when selected from the chart.
MINIMUM SIZE OVERLOAD PROTECTION
NEC 430.32(A)(1))
Figure 1. Determining the minimum size overloads based
upon service factor and temperature rise.
based upon the full load current rating, in amps, listed on
the motor’s nameplate:
• Motors, with a marked service factor not less than
1.15, use 125 percent
• Motors, with a marked temperature rise not over
40°C, use 125 percent
• All other motors – 115% x FLA

Figure 1 (See Figures 1 and 2)

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 codeissues
OCPD CONTROLLER
OVERLOAD CHART • 430.52(c)(1) • 430.83
• TABLE 430.52
DISCONNECTING OLS
Amperage Overload Units MEANS • 430.32(C)
FUSES TD • 430.110(a) OL CHART
• 430.57 • H1052
20.6 - 23.3 H1042 IF MOTOR
23.4 - 26.0 H1043 WILL START
26.1 - 30.5 H1044
MBJ GES NOTE: NEC 430.32(C), FPN
30.6 - 33.6 H1045
GEC RECOMMENDS USING CLASS
33.7 - 37.9 H1046 20 OR CLASS 30 OLS.
38.0 - 42.9 H1047
SIZING PROCEDURE
43.0 - 48.2 H1048 50 HP MOTOR
SERVICE FACTOR OF 1.15 OR GREATER
48.3 - 54.6 H1049 • FLA x 140% = OL RATING 3Ø, 46O V
54.7 - 61.2 H1050 TEMPERATURE RISE OF NOT OVER 40°C DES. B; NP-62 A;
• FLA x 140% = OL RATING TR-40°C; SF 1.15
61.3 - 67.6 H1051 ALL OTHER MOTORS
MOTOR NAMEPLATE
67.7 - 75.9 H1052 • FLA x 130% = OL RATING
• 430.32(C)
76.0 - 87.1 H1053
87.2 - 97.5 H1054 FINDING MOTOR OVERLOAD PROTECTION
97.6 - 109.0 H1055 Sizing OL’s using fuses
110.0 - 122.0 H1056
Step 1: Finding FLA
123.0 - 135.0 H1057 430.6(A)(2)
Nameplate = 62 A

Step 2: Finding percentage

Figure 2. Overload chart listing the size OL based on the 430.32(C)
SF = 140%
nameplate amps of a motor. in Figure 1. TR = 140%
Note that the chart covers specific amp ranges
for a 460 volt, 3-phase motor. Step 3: Calculating FLA
430.32(C)
62 A x 140% = 86.8 A
Figure 2 Step 4: Selecting TD fuses
430.32(C)
TD fuses are not allowed to be sized
at 140%
MAXIMUM SIZE OVERLOAD PROTECTION
Sizing OLs in controller
430.32(C)
Step 1: Calculating FLA
The running overload protection (overload relay) shall 430.6(A)(2); 430.32(C)
be allowed to be selected at higher percentages if the 62 A x 140% = 86.8 A

percentages of 430.32(A)(1) are not sufficient. The run- Solution: The size overloads are selected from
a manufacturer's chart based on 86.8
ning overload protection shall be selected to trip or shall amps.
be rated no larger than the following percentages of the Note: The OL units can be calculated at 86.8
motor’s (nameplate) full load current rating: amps and can be increased in increments
not to exceed 86.8 amps.
• Motors, with marked service factor not less than
1.15, use 140% x FLA
MAXIMUM SIZE OVERLOAD PROTECTION
• Motors, with a marked temperature rise not over NEC 430.32(C)
40°C, use 140% x FLA
Figure 3. Determining the maximum size overloads based upon service
• All other motors - 130% x FLA factor and temperature rise.

(See Figure 3) Figure 3

ILLUSTRATIONS COURTESY OF GRAYBOY, INC.

SIZING THE CONTROLLER TO START AND SIZING DISCONNECTING MEANS

STOP THE MOTOR
430.81 AND 430.83
The sizes and types of motor controllers are required to
be installed with horsepower ratings at least equal to the
motor to be controlled. However, there is an Exception
to this rule for motors rated at and below a certain
horsepower rating.
430.110(A)
Either the disconnecting means for motor circuits must
have an ampere rating of at least 115 percent of the full
load current rating of the motor per 430.110(A) or it
must be horsepower rated and capable of de-energizing
locked rotor currents per Tables 430.251(A) and (B).
For detailed rules, see 430.109. (See Figure 4)

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 codeissues
LOCATION OF THE DISCONNECTING MEANS
QUICK CALC FOR THE CONTROLLER AND MOTOR
THE DISCONNECT IS SIZED 430.102 AND 430.107
IN AMPS AS FOLLOWS:
A motor and its driven machinery or load shall be
OCPD • 62 A x 115% = 71.3 A
• 430.52(C)(1)
installed within sight of the controller for the motor.
• TABLE 430.52 CONTROLLER This rule provides safety for electricians and maintenance
• 3-POLE W/OL'S personnel while servicing such machinery and circuit
CB • 430.83(A)(1)
• 3-POLE • 430.32(A)(1) elements.

WITHIN SIGHT
ARTICLE 100; 430.102
The disconnecting means shall be installed within sight of
DISCONNECTING the motor controller. All of the ungrounded conductors
MEANS
• 430.110(A) shall be disconnected from both the motor and controller
MBJ GEC • 430.109(A)(1)
supplying the motor circuit. The disconnecting means
GES
shall be installed within sight of the motor and not more
Sizing Controller
50 HP MOTOR than 50 ft. from the motor. If such disconnecting means
Step 1: Applying derating factors 3Ø,460 V is not installed within 50 ft. of the motor, other provi-
430.110(A) DESIGN B
sions for disconnecting the motor must be made. The
62 HP x 115% = 71.3 A FLA PER
TABLE 430.250 controller has a direct relationship to the disconnecting
Solution: The disconnect must be equal IS 62 AMPS means and must be installed within sight and within
to least 71.3 amps.
50 ft. of the disconnecting means. The motor does not
have a direct relationship with the controller.
NEC 430.110(A)
Note that a disconnecting means is always required to
Figure 4. The disconnecting means must be sized in amps by multiplying be located so it can be seen from the controller location.
the motors FLA by 115%
A single disconnecting means is permitted to be located
Figure 4 adjacent to a group of coordinated controllers mounted

POWER SUPPLY
• 600 V OR LESS POWER SUPPLY
600 V OR LESS • OVER 600 V
DISCONNECT CONTROLLER HAS A WARNING
• 430.102(B) SIGN GIVING LOCATION OF
DISCONNECTING MEANS LOCK
LOCK
CONTROLLER
WITHIN SIGHT DISCONNECTING MEANS IS
LOCKED IN OPEN POSITION
DISCONNECTING MEANS IS
WITHIN SIGHT LOCKED IN OPEN POSITION
• NEC ARTICLE 100
NO ADDITIONAL OUT OF SIGHT
DISCONNECT NEC LOOP • NEC ARTICLE 100
REQUIRED CLEARANCE 110.26(A) NO ADDITIONAL DISCONNECT
. REQUIRED
MARKED 110.22
DIRECTORY 408.4
ILLUSTRATIONS COURTESY OF GRAYBOY, INC.

SIZING 430.110
FUSEHOLDERS 430.57

(a) DISCONNECTING MEANS WITHIN SIGHT OF MOTOR (b) DISCONNECTING MEANS OUT OF SIGHT OF MOTOR
AND LOCKED IN THE OPEN POSITION. LOCKED IN THE OPEN POSITION.

LOCKED IN THE OPEN POSITION

430.102(B)
Figure 6(a). Locating the disconnecting means to disconnect power conductors to motors rated 600 volts or less or for motors rated over 600 volts respectively

Figure 5(a)

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 codeissues
adjacent one to another such as on a multi-motor contin-
uous process machine. For further information pertaining
to sizing, selecting, and locating such controllers and dis-
connecting means, review 430.102, 430.103, 430.107,
and 430.109 very carefully.
LOCKED IN THE OPEN POSITION
430.102(A) AND (B)
Section 430.102(A) and (B) permits the disconnect on the
line side of the controller, if within sight and within 50 ft.,
and capable of being locked open, to serve as the discon-
necting means for both the controller and motor. It is
important to note that the motor shall be installed within
sight and within 50 ft. of the disconnecting means of the
controller. (See Figures 5(a) and 5(b))
CANNOT BE LOCKED IN THE OPEN POSITION
430.102(A), Ex. 1; 430.102(B)
For motors rated 600 volts or less, an additional discon-
necting means must be mounted at the motor and within
sight if the disconnecting means installed at the controller
cannot be locked in the open position. (See Figure 6) The
controller disconnecting means for a motor branch-cir-
DOES NOT COMPLY
CONTROLLER
cuit over 600 volts is allowed to be located out of sight
of the motor branch circuit controller and motor.
However, the controller must have a warning label that
marks and lists the location and identification of the dis-
connecting means. To completely satisfy this rule, such
disconnecting means must be capable of being locked in
the open position. (See Figure 5(b))
APPLYING EXCEPTION
430.102(B)
The Ex. to 430.102(B) does not require an additional dis-
connect to be installed within sight of the motor, where the
disconnecting means would be impractical or increase haz-
ards. An additional disconnecting means is not required
where it is located in an industrial installation that has
written safety procedures and only qualified employees are
allowed to work on the equipment involved.
Design Tip: Remote control circuits shall have their
disconnecting means located immediately adjacent to
the disconnecting means used to disconnect the branch
circuit conductors supplying the controller and motor.
Sometimes an interlock in the disconnect for the motor
controller, which allows the controller, motor, and
remote-control circuit to be disconnected simultaneously,
is used for this purpose.
Part 2 will appear in the October issue of necdigest ®

MOTOR DISCONNECTING MEANS

IS WITHIN SIGHT OF
CONTROLLER
PANELBOARD DISCONNECT CONTROLLER
COMPLIES
W/LOCKED DOOR • WITHIN 50 FT. WITHIN SIGHT
• 430.102(B), Ex. • WITHIN SIGHT
LOCKABLE CB OF MOTOR
NEC LOOP IN PANELBOARD
LOCATION 430.102 • 430.102(B), Ex.
MARKING 110.22 POWER SUPPLY
SIZING
• NONAUTOMATIC 430.110(A) • 600 V OR LESS
SIZING
• FOR FUSES 430.57 DISCONNECT NOT
SIZING WITHIN SIGHT
• AUTOMATIC CB 430.58 CONTROLLER • NEC ARTICLE 100
COMBINATION MOTOR
PROTECTION 430.55 MOTOR • 600 V OR LESS
ILLUSTRATIONS COURTESY OF GRAYBOY, INC.

LOCKING MEANS

DISCONNECTING MEANS NOT WITHIN SIGHT OF MOTOR

LOCKED IN THE OPEN POSTION
NEC 430.102(B), Ex. CANNOT BE LOCKED IN THE
OPEN POSTION
NEC 430.102(A), Ex. 1
Figure 6(b). The locked door of a panelboard cannot serve as the required Figure 7(a). If the disconnecting means is within sight and 50 ft. of controller
disconnecting means for a motor. However, an individual locked and can't be locked in the open position, an additional
circuit breaker can serve as such. disconnecting means must be installed by the motor.
.

Figure 6
Figure 5(b)

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