MOTOR CIRCUITS, CONTROLLERS

AND FIRE PUMP - FROM PEC PART 1

18 MARCH 2016
A. STEPS IN DESIGN OF ELECTRIC MOTOR CIRCUIT FROM PEC 4.30
1. Select branch circuit
conductors rated atleast
125% of motor full load
current.
2. Select branch-circuit
protective device to
protect against short
circuits and grounds in
motor circuit.
3. Select controller suited
to the load and to the
supply system.
4. Select running overload
protection to open the
circuit on overload up to
and including stalled
rotor current.
5. Select disconnecting
means to disconnect
both motor and
controller from all
ungrounded supply
conductors.
Calculations :

1. Solving for minimum size of branch circuit conductor ;

For 25 HP Motor at 460V , FLA = 34 A (From Table 4.30.14.4, page 734)

‫ ≥ ܧܮܤܣܥܫ‬ሺ34 ‫ܣ‬ሻ ܺ 1.25 (From Article 4.30.2.2 , page 685)

‫ ≥ ܧܮܤܣܥܫ‬ሺ34 ‫ܣ‬ሻ ܺ 1.25

ࡵ࡯࡭࡮ࡸࡱ ≥ ૝૛. ૞ ࡭

Based on Table 3.10.16 on page 350, From Column of 90 deg. C , Use : 3 x 8.0 MM2 THHN Wire
with ampacity of 55 A.

For Correction Factor, based on Ambient Temperature. For Outdoor Installations in cable tray,
Assume Ambient Temperature of 36 Deg. C to 40 Deg. C, Correction Factor is 0.91.

‫ = ܧܮܤܣܥܫ‬55 ‫ ܺ ܣ‬0.91

ࡵ࡯࡭࡮ࡸࡱ = ૞૙. ૙૞ ࡭

૞૙. ૙૞ ࡭ ≥ ૝૛. ૞ ࡭

Therefore , Use 3 x 8.0 MM2 THHN Wire

TABLE 4.30.14.4 FULL LOAD CURRENTS FOR 3 PHASE AC MOTORS
TABLE 3.10.1.16 ALLOWABLE AMPACITIES OF INSULATED CONDUCTORS
(0-2000 Volts) - LOW VOLTAGE APPLICATION
2. Sizing for Overcurrent Protection ;
Given Data :
25 HP, 460 V, 3PH Motor, FLA = 34 A (From Table 4.30.14.4, page 734)
‫ ≥ ܧܼܫܵܤܥ‬ሺ34 ‫ܣ‬ሻ ܺ 2.5 (From Article 4.30.4.2 and Table
4.30.4.2 , page 698 & 700
respectively)
‫ ≥ ܧܼܫܵܤܥ‬85 ‫ܣ‬

Use 100 AT , 3P, Inverse Time Circuit Breaker (MCCB) - (From Article 2.40.1.6
page 169 Standard Ampere ratings for Fuses and Circuit Breakers)
TABLE 4.30 .4.2 MAXIMUM RATING OR SETTING OF MOTOR BRANCH SHORT
CIRCUIT AND GROUND FAULT PROTECTIVE DEVICES
3. Sizing of Motor Controller (Magnetic Starters)

From Article PEC 4.30.7.3, page 711 - The Controller shall have a rating specified in; a)
Horsepower ratings, Controllers, other than inverse time circuit breaker and molded case
switches , shall have horsepower ratings at the application voltage not lower than the
horsepower rating of the motor.

TYPICAL DATA FOR NEMA (NATIONAL ELECTRICAL MANUFACTURERS

ASSOCIATION) CONTROLLER FROM MANUFACTURER.
Table 1: Rating for Three-Phase Single-Speed Full-Voltage Magnetic Controllers for
Plug-Stop, Plug-Reverse, or Jogging Duty
Size of Continuous Horsepower at Service
Controller Current 60 Hertz 50 Hertz 60 Hertz Limit
Rating Current
200 Volts 230 Volts 380 Volts 460 Volts
(Amp) (Amp)
0 18 1-1/2 1-1/2 1-1/2 2 21
1 27 3 3 5 5 32
2 45 7-1/2 10 15 15 52
3 90 15 20 30 30 104
4 135 25 30 50 60 156
5 270 60 75 125 150 311
6 540 125 150 250 300 621

From the above data and for 25 HP,460 V Motor with 34 A Full Load Current, Use
NEMA Size 3 Controller.
4. Setting of Overload Relay (PEC Page 690 and 693)

PEC 4.30.3.1 General. It specifies overload devices intended to protect motors,

motor-control apparatus, and motor branch-circuit conductors against excessive
heating due to motor overloads and failure to start.

PEC 4.30.3.2 Continuous-Duty Motors. Each continuous-duty motor rated more

than 1 horsepower shall be protected against overload by an overload device
selected to trip or rated at not more than the following percent of the motor
nameplate full-load current rating.

Motors with a marked S.F. not less than 1.15 ------------- 125% (140%)
Motors with marked temp. rise not over 400C ------------ 125% (140%)
All other motors --------------------------------------------- 115% (130%)

(Modification of the above value shall be permitted if the selected trip or

rating is not sufficient to override the starting current of the motor, in which
case shall not exceed the limit enclosed in parenthesis (Article 4.30 3.2 A &
C)
4.1 Setting of Overload Relay

Calculation :

Given Data :

25 HP Motor, 460 V, 3PH, FLA = 34 A

OL setting = 34 A (1.30) (From Article 4.30.3.2 C)

OL Setting = 44.2 A

Choose an overload relay with a setting range from 40 to 100 Amps and Set at 50 A,
Class 20 Overload Relay.
4.2 Overload Relays Trip Class

A. NEMA Class 10 - operates in less than 10 seconds at 600 percent of the full load
amperes of the motor during starting.

B. NEMA Class 20 - operates in less than 20 seconds at 600 percent of the full load
amperes of the motor during starting.

C. NEMA Class 30 - for high inertia industrial load applications, operates in less than
30 seconds.
5. Determining Minimum Size of Disconnecting Means

Disconnect
Motors and controllers must be provided with a means of safely disconnecting
them from their source of supply such that the maintenance of the controller, the
motor, and its driven equipment can be accomplished without any hazard to
personnel. The disconnect must open all ungrounded supply conductors, and also
be gang-operated so that the operating mechanism opens all poles simultaneously.
The disconnecting means must be located in sight from the motor location.

From Article PEC 4.30.9.10, page 721 - The disconnecting means for motor
circuits rated 600 V, nominal, or less shall have an ampere rating not less than 115
percent of the full-load current rating of the motor.

Calculation :

Motor Given Data :

25 HP, 460 V, 3 PH FLA = 34 A

Disconnecting Means = 34 A x 1.15

Disconnecting Means = 39.1 A

Use 40 A, 3P, 480 V, Disconnect Switch in NEMA 3R or NEMA 4X Enclosure

5.1 NEMA ENCLOSURE CLASSIFICATION

1.1. NEMA 1 – General Purpose Enclosures: It is intended for indoor

applications. It provides a degree of protection against falling dirt in
locations where unusual service conditions do not exist.

1.2. NEMA 3R – Rain-Resistant Enclosures: It is used for outdoor applications

to provide degree of protection against rain and sleet

1.3. NEMA 12 – Dust-Tight Industrial Enclosures: It is for indoor applications

used primarily to provide a degree of protection against dust, falling dirt, and
dripping non-corrosive liquid.

1.4. NEMA 4 / 4X – Water, Dust-Tight, and Corrosion-Resistant Enclosures:

These are intended for indoor or outdoor applications. Both types are used
primarily to provide degree of protection against windblown dust and rain,
splashing water, and hose-directed water. In addition, the Type 4X
enclosure is also intended to provide degree of protection against corrosion.

1.5. NEMA 7 – Hazardous Location Enclosures: It is intended for use in

hazardous locations classified as Class 1, Group A, B, C, or D, as defined in
PEC.
B. SAMPLE CALCULATION FOR MULTIMOTOR AND COMBINATION LOAD
EQUIPMENT (PEC ART. 4.30 2.5)
1. Select feeder conductors for the
combination of motor loads.
(Article 4.30.2.4 page 688)
2. Select protective device for the
combination of motor loads in
accordance to Article 4.30.5.2
page 705.
3. Select feeder conductors for
Lighting Panel in accordance to
Article 2.15.1.2. A .1. page 91.
4. Select feeder conductors for
the combination of lighting
panel and combination of
motor loads. (Article 4.30.2.4 &
2.5 page 687 & 688)
5. Select protective device for the
combination of motor loads and
lighting panel in accordance to
Article 4.30.5.2 page 705.
Calculations :

1. Solving for minimum feeder conductors size supplying combination of motor loads;

Given Data :

1 - 50 HP Motor at 460V , FLA = 65 A , 1- 30 HP Motor at 460 V, FLA = 40 A

2 - 10 HP Motor at 460 V, FLA = 14 A

(From Table 4.30.14.4, page 734)

‫ ≥ ܧܮܤܣܥܫ‬ሺ65 ‫ܣ‬ሻ ܺ 1.25 + ሺ40 ‫ ܣ‬+ 14 ‫ ܣ‬+ 14‫ܣ‬ሻ (From Article 4.30.2.4 , page 687)

ࡵ࡯࡭࡮ࡸࡱ ≥ ૚૝ૢ. ૛૞ ࡭

Based on Table 3.10.16 on page 350, From Column of 90 deg. C , Use : 3 x 80 MM2 THHN Wire
with ampacity of 205 A.

For Correction Factor, based on Ambient Temperature. For Outdoor Installations in cable tray,
Assume Ambient Temperature of 36 Deg. C to 40 Deg. C, Correction Factor is 0.91.

‫ = ܧܮܤܣܥܫ‬205 ‫ ܺ ܣ‬0.91

ࡵ࡯࡭࡮ࡸࡱ = ૚ૡ૟. ૞૞ ࡭

૚ૡ૟. ૞૞ ࡭ ≥ ૚૝ૢ. ૛૞ ࡭

Therefore , Use 3 x 80 MM2 THHN Wire

2. Sizing for Overcurrent Protection of Combination of Motor Loads ;
From 4.30.5.2 A feeder supplying a specific motor load(s) consisting of conductor
sizes based on 4.30.2.4 shall be provided with a protective device having a rating not
greater than the largest rating or setting of the branch circuit short and ground fault
protective device for any motor supplied by the feeder , plus the sum of the full load
currents of the other motors of the group.
‫ ≤ ܧܼܫܵܤܥ‬ሺ175ሻ + 40 + 14 + 14 (From Article 4.30.5.2, page 705)
‫ ≤ ܧܼܫܵܤܥ‬243 ‫݉ݑ݉݅ݔܽܯ ܣ‬
‫ ≤ ܧܼܫܵܤܥ‬243 ‫݉ݑ݉݅ݔܽܯ ܣ‬

Use 225 AT , 3P, Inverse Time Circuit Breaker (MCCB) - (From Article 2.40.1.6
page 169 Standard Ampere ratings for Fuses and Circuit Breakers)
Calculations :

3. Solving for minimum size of feeder conductor for Lighting Panel;

From Article 2.15.1.2 Minimum Rating and Size for A) Feeders not more than 600 Volts. Feeder
Conductors shall have an ampacity not less than required to supply the load. The minimum feeder
circuit conductor size , before the application of any adjustment factor or correction factors , shall
have an amapcity not less than the non-contiunous load plus 125 percent of the continuous load.

FLA = 64.98A

‫ ≥ ܧܮܤܣܥܫ‬ሺ64.98 ‫ܣ‬ሻ ܺ 1.25 (From Article 4.30.2.2 , page 685)

‫ ≥ ܧܮܤܣܥܫ‬ሺ64.98 ‫ܣ‬ሻ ܺ 1.25

ࡵ࡯࡭࡮ࡸࡱ ≥ ૡ૚. ૛૛૞ ࡭

Based on Table 3.10.16 on page 350, From Column of 90 deg. C , Use : 2 x 30 MM2 THHN Wire
with ampacity of 115 A.

For Correction Factor, based on Ambient Temperature. For Outdoor Installations in cable tray,
Assume Ambient Temperature of 36 Deg. C to 40 Deg. C, Correction Factor is 0.91.

‫ = ܧܮܤܣܥܫ‬115 ‫ ܺ ܣ‬0.91

ࡵ࡯࡭࡮ࡸࡱ = ૚૙૝. ૟૞ ࡭

૚૙૝. ૟૞ ࡭ ≥ ૡ૚. ૛૛૞ ࡭

Therefore , Use 2 x 30 MM2 THHN Wire

Calculations :

4. Solving for minimum feeder conductors size supplying combination of motor loads and
lighting panel;

For Combined Ampacity

Combination Motor ‫ ≥ ܧܮܤܣܥܫ‬ሺ65 ‫ܣ‬ሻ ܺ 1.25 + ሺ40 ‫ ܣ‬+ 14 ‫ ܣ‬+ 14‫ܣ‬ሻ = 149.25 ‫ܣ‬

Lighting Panel ‫ ≥ ܧܮܤܣܥܫ‬ሺ64.98 ‫ܣ‬ሻ ܺ 1.25 = 81.225 ‫ܣ‬ (From Article 4.30.2.4 , page 687)

Combined Total Ampacity ࡵ࡯࡭࡮ࡸࡱ ≥ ૚૝ૢ. ૛૞ ࡭ + ૡ૚. ૛૛૞ ࡭

Combined Total Ampacity ۷۱‫ۯ‬۰‫ۺ‬۳ ≥ ૛૜૙. ૝ૠ૞ ‫ۯ‬

Based on Table 3.10.16 on page 350, From Column of 90 deg. C , Use : 3 x 125 MM2 THHN
Wire with ampacity of 265 A.

For Correction Factor, based on Ambient Temperature. For Outdoor Installations in cable tray,
Assume Ambient Temperature of 36 Deg. C to 40 Deg. C, Correction Factor is 0.91.

‫ = ܧܮܤܣܥܫ‬265 ‫ ܺ ܣ‬0.91

ࡵ࡯࡭࡮ࡸࡱ = ૛૝૚. ૚૞ ࡭

૛૝૚. ૚૞ ࡭ ≥ ૛૜૙. ૝ૠ૞ ࡭

Therefore , Use 3 x 125 MM2 THHN Wire

5. Sizing for Overcurrent Protection of Combination of Motor Loads and
Lighting Panel :
From 4.30.5.2 as discussed in Item B.2 :
For Combination of Motor Loads
‫ ≤ ܧܼܫܵܤܥ‬ሺ175ሻ + 40 + 14 + 14 (From Article 4.30.5.2)
‫ ≤ ܧܼܫܵܤܥ‬243 ‫ܣ‬
For Lighting Panel
‫ ≤ ܧܼܫܵܤܥ‬ሺ64.98‫ݔ‬1.25ሻ (From Article 4.30.5.2)
‫ ≤ ܧܼܫܵܤܥ‬81.225 ‫ܣ‬
‫ ≤ ܤܥ ݂݋ ݃݊݅ݐܴܽ ܾ݀݁݊݅݉݋ܥ‬243 + 81.225 ‫ = ܣ‬324 ‫݉ݑ݉݅ݔܽܯ ܣ‬
Use 300 AT , 3P, Inverse Time Circuit Breaker (MCCB) - (From Article 2.40.1.6
page 169 Standard Ampere ratings for Fuses and Circuit Breakers)
Note : There is no provision in Article 4.30.5.2 which permits the use "the next higher
size, rating or setting" of the protective device for a motor feeder when the calculated
maximum rating does not correspond to a standard size of device.
C. PEC ARTICLE. 6.95 FIRE PUMPS
• The general philosophy behind Code articles is that circuit protection will shut
down equipment before letting the supply conductors melt from overload.

• Art. 6.95 Fire Pumps depart from this philosophy.

• The idea is that the fire pump motor must run, no matter what; it supplies water
to facility’s fire protection piping, which in turn supplies water to the sprinkler
system and fire hoses.

• Art. 6.95 contains many requirements to keep that supply of water uninterrupted.

• Locating the pump so as to minimize its exposure to fire.

• Ensuring that the fire pump and its jockey pump have a reliable source of power.
It makes sense to keep fire pump wiring independent.
C.1 SAMPLE CALCULATION FOR DESIGN OF FIRE PUMP CIRCUIT (PEC
ART. 6.95)
1. From Article 2.40.1.4 & 6.95
1.6.d (page 165 &1336
respectively) a) Power Loss
Hazard – Conductor overload
protection shall not be
required where the
interruption of the circuit
would create hazard , such as
in a material – handling
magnet circuit or fire pump
circuit . Short circuit
protection shall be provided.
2. It is important to consider the
lock rotor current (6 x Full
Load Current) during starting
of the fire pump motor.
C.2 Motor Circuit Protector (MCP) Type of Circuit Breaker
1. Typical Motor Circuit
Protector (MCP) Curve
from Manufacturer – Short
Circuit Circuit Protection
Only.
C.3 Thermal Magnetic (MCCB) Type of Circuit Breaker

1. Typical Thermal Magnetic

Type (MCCB) Curve
from IEEE Standard
242 2001 – Overload
and Short Circuit
Circuit Protection.
C.4 Sizing of Overcurrent Protection for Fire Pump Circuit ;
From Table 4.30.4.2, at Column of Instantaneous Trip Circuit Breaker, use 800
percent of Full Load Current of Fire Pump Motor.
Given : FLA = 150 A at 460 V
‫ ≥ ܧܼܫܵܤܥ‬ሺ150 ‫ܣ‬ሻ ‫ ݔ‬8 (From Article 4.30.4.2 & 6.95.1.6d)
‫ ≥ ܧܼܫܵܤܥ‬1200 ‫ܣ‬

Use 250 A , Set at 1250A , 3P, Motor Circuit Protector (MCP) - (See attached
Catalog from Manufacturer)
MOTOR CIRCUIT PROTECTOR PRODUCT DATA FROM EATON
CURRENT RATINGS FOR LOW VOLTAGE XLPE CABLE
Calculations :

C.5 Sizing of feeder conductor for Fire Pump ;

Since the feeder conductors for fire pump circuit does not have an overload protection, It is
important for fire pump circuit to have an insulation coordination study to ensure that cables can
withstand the available fault current .

Given : ‫ܫ‬3ܲ‫ = ܪ‬52 ݇‫݈ܽܿ݅ݎݐ݁݉݉ݕݏ ܣ‬

‫ = ܣܮܨ‬150 ‫ܣ‬

‫ ≥ ܧܮܤܣܥܫ‬ሺ150 ‫ܣ‬ሻ ܺ 1.25 (From Article 6.95 C.2 page 1336)

ࡵ࡯࡭࡮ࡸࡱ ≥ ૚ૡૠ. ૞ ࡭

Based on the attached Oman Cable Catalogue , Use : 3 C x 95 MM2 XLPE with Ampacity of
226 A in PVC Duct.

ࡵ࡯࡭࡮ࡸࡱ = ૚ૡૠ. ૞ ࡭

૛૛૟ ࡭ ≥ ૚ૡૠ. ૞ ࡭
MOTOR CIRCUIT PROTECTOR AND XLPE CABLE - TIME CURRENT
CURVE
MOTOR CIRCUIT PROTECTOR PRODUCT DATA FROM EATON