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| Use only 600 volt wire. Lamp cord, extension cords are not rated 600 volt. Use copper wire only. Aluminum wire is fire risk and should be avoided or installed by professional. 30 amp breaker use 10 gauge / 120-240 volt 30 amp outlet can be installed on 30 amp breaker only/ use 10 gauge wire ... cannot be connected to 15-20-40 amp breaker.  Orange/ #10 gauge wire, with ground ... 30 amp capacity. Safe maximum: 30 x 80% = 24 amps. Buy: 10-2 gauge/ 30 amp 10-3/ 30 amp Southwire electric tools |
Yellow
12 gauge 20 amp 120 volt 20 amp outlet can be installed on 20 amp breaker, but not 15 amp breaker/ use 12 ga wire. ... cannot be connected to 30-40 amp breaker. 1  Yellow/ #12 gauge wire, with ground ... 20 amp capacity. Safe maximum 16 amps. Buy: 12-2 gauge/ 20 amp 12-3/ 20 amp NMB is house wiring UF is underground Rolls of stranded wire HOOK UP Wires |
White
14 gauge 15 amp 120 volt 15 amp outlet, AFCI, GFCI, timer, switch etc can be installed on 15 or 20 amp breaker. Never connect 15 gauge wire to 20-30-40 amp breaker.  White/ #14 gauge wire, with ground ... 15 amp capacity. Safe maximum 12 amps. Buy: 14-2 gauge/ 15 amp 14-3/ 15 amp NMB is house wiring UF is underground |
| 50-60
amp breaker use 6 gauge / 240 volt 50 outlet can be installed on 50 amp breaker only  Buy: 6-2 wire Southwire electric tools NMB is house wiring UF is underground |
40-50
amp breaker use 8 gauge / 240 volt 40 amp outlet can be installed on 40 or 50 amp breaker only  Buy: 8-2 wire Southwire electric tools NMB is house wiring UF is underground |
  Copper ground wire. Every device, load, metal enclosure etc must be grounded. Ground wire must be continuous throughout installation, never switched on-off, never used as a Neutral wire. Generally ... use same size as other wire in circuit Buy: 12 gauge copper ground wire Ground wire Green ground wire Ground pigtails Ground rods/ ground clamps at Amazon |
 Non metallic flexible cables must carry ground wire, but do not have hazard of short circuit causing injury from shock. Armored steel cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure. All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes. Movement, damage and deterioration are major cause of electrical failure. Buy: Non-metallic flexible conduit Power whip Armored cable Southwire armored cable cutter Pull boxes |
 Electrical tools must be insulated. Always best to disconnect power, but insulation failure, lack of proper grounding, grounded neutral, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems still pose a risk to anyone working on electric power ... even when breaker is off. Buy: Electrician tools kits KLEIN TOOLS Tools kits IRWIN tools KNIPEX Telephone cable knife Low Voltage Mounting Bracket for Telephone |
 600 volt 12 ga Stranded wire ot THHN wire is good for conduit with multiple wires ... but stranded cannot be installed under screw terminals on outlets, switches, timers etc without risk ... of heat causing splayed strands ....that come loose ... and begin to arc. Connect stranded to short piece of solid copper wire, and attach solid to screw terminal. Do not solder residential or commercial wiring. Project wire, extension cords, thermostat, bell and automotive wire are not rated for residential or commercial wiring. Only wire maked 600 volt can be used for permanent household wiring. Buy: Southwire 600 volt stranded wire Rolls of stranded wire HOOK UP Wires |
 Protect wiring from damage Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable. -Code says: Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15 Buy End cutting nippers at Amazon |
  Electrically insulated tools When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistance and heat on wire and creates possible weak point. Buy tools: KLEIN TOOLS Wire strippers at Amazon Electric Wire Stripping Machine Linesman pliers Utility knife at Amazon |
 Multimeters Voltage is tested across two separate wires. Ohms or resistance is tested across both ends of same wire. Amperage is tested along one or two points on same wire. Buy: Analog multimeter Multimeters at Amazon Klein multimeter Electric testers at Amazon Clampmeter for testing amp flow on line |
 GFCI circuit breaker A GFCI circuit breaker will protect all boxes on circuit. Circuit must be grounded. Ground wire must be continuous and connected to each piece of equipment. White wire on circuit breaker must be connected to Neutral busbar inside the breaker panel. Buy GFCI circuit breakers |
Push down 1" wide Push down breaker Plug-in breaker Buy single-pole: Choose from 15 to 60 amp Eaton CL series Siemens 15-60 amp Single-pole tandem breaker Tandem breakers |
Push down 2" wide Push down breaker Plug-in breakers Buy double-pole: Choose from 15 to 125 amp Choose from 15 amp to 200 amp Eaton CL series circuit breaker Siemens circuit breaker Double pole GFCI |
| Motor
terminology/ source: Leeason eBusiness Center www. lesson.com Actuator: A device that creates mechanical motion by converting various forms of energy to rotating or linear mechanical energy. Adjustable Speed Drive: A mechanical, fluid or electrical device that variably changes an input speed to an output speed matching operating requirements. AGMA (American Gear Manufacturers Association): Standards setting organization composed of gear products manufacturers and users. AGMA standards help bring uniformity to the design and application of gear products. Air-Over (AO): Motors for fan or blower service that are cooled by the air stream from the fan or blower. Alternating Current (AC): The standard power supply available from electric utilities. Ambient Temperature: The temperature of the air which, when coming into contact with the heated parts of a motor, carries off its heat. Ambient temperature is commonly known as room temperature. Ampere (Amp): The standard unit of electric current. The current produced by a pressure of one volt in a circuit having a resistance of one ohm. Armature: • The rotating part of a brush-type direct current motor. • In an induction motor, the squirrel cage rotor. Axial Movement: Often called “endplay.” The endwise movement of motor or gear shafts. Usually expressed in thousandths of an inch. Back Driving: Driving the output shaft of a gear reducer – using it to increase speed rather than reduce speed. Worm gear reducers are not suitable for service as speed increases. Backlash: Rotational movement of a gear reducer’s output shaft clockwise and counter clockwise, while holding the input shaft stationary. Usually expressed in thousandths of an inch and measure at a specific radius at the output shaft. Bearings: Sleeve: Common in home-appliance motors. Ball: Used when high shaft load capacity is required. Ball bearings are usually used in industrial and agricultural motors. Roller: Use on output shafts of heavy-duty gear reducers and on some high-horsepower motors for maximum overhung and thrust load capacities. Breakdown Torque: The maximum torque a motor can achieve with rated voltage applied at rated frequency, without a sudden drop in speed or stalling. Brush: Current-conducting material in a DC motor, usually graphite, or a combination of graphite and other materials. The brush rides on the commutator of a motor and forms an electrical connection between the armature and the power source. Canadian Standards Association (CSA): The agency that sets safety standards for motors and other electrical equipment used in Canada. Capacitance: As the measure of electrical storage potential of a capacitor, the unit of capacitance is the farad, but typical values are expressed in microfarads. Capacitor: A device that stores electrical energy. Used on single-phase motors, a capacitor can provide a starting “boost” or allow lower current during operation. Center Distance: A basic measurement or size reference for worm gear reducers, measured from the centerline of the worm to the centerline of the worm wheel. Centrifugal Starting Switch: A mechanism that disconnects the starting circuit of a motor when the rotor reaches approximately 75% of operating speed. Cogging: Non-uniform or erratic rotation of a direct current motor. It usually occurs at low speeds and may be a function of the adjustable speed control or of the motor design. Commutator: The part of a DC motor armature that causes the electrical current to be switched to various armature windings. Properly sequenced switching creates the motor torque. The commutator also provides the means to transmit electrical current to the moving armature through brushes that ride on the commutator. Counter Electromotive Force: Voltage that opposes line voltage caused by induced magnetic field in a motor armature or rotor. Current, AC: The power supply usually available from the electric utility company or alternators. Current, DC: The power supply available from batteries, generators (not alternators), or a rectified source used for special applications. Duty Cycle: The relationship between the operating time and the resting time of an electric motor. Motor ratings according to duty are: • Continuous duty, the operation of loads for over one hour. • Intermittent duty, the operation during alternate periods of load and rest. Intermittent duty is usually expressed as 5 minutes, 30 minutes or one hour. Efficiency: A ratio of the input power compared to the output, usually expressed as a percentage. Enclosure: The term used to describe the motor housing. The most common industrial types are: Open Drip Proof (ODP), Totally Enclosed Fan Cooled (TEFC), Totally Enclosed Non-Ventilated (TENV), Totally Enclosed Air Over (TEAO). Endshield: The part of a motor that houses the bearing supporting the rotor and acts as a protective guard to the internal parts of the motor; sometimes called endbell, endplate or end bracket. Excitation: The act of creating magnetic lines of force from a motor winding by applying voltage. Explosion-Proof Motors: These motors meet Underwriters Laboratories and Canadian Standards Association standards for use in hazardous (explosive) locations, as indicated by the UL label affixed to the motor. Locations are considered hazardous because the atmosphere does or may contain gas, vapor, or dust in explosive quantities. Field: The stationary part of a DC motor, commonly consisting of permanent magnets. Sometimes used also to describe the stator of an AC motor. Flanged Reducer: Usually used to refer to a gear reducer having provisions for close coupling of a motor either via a hollow (quill) shaft or flexible coupling. Most often a NEMA C face motor is used. Foot-Pound: Energy required to raise a one-pound weight against the force of gravity the distance of one foot. A measure of torque. Inch-pound is also commonly used on smaller motors and gear reducers. An inchpound represents the energy needed to lift one pound one inch; an inchounce represents the energy needed to lift one ounce one inch. Form Factor: Indicates how much AC component is present in the DC output from a rectified AC supply. Unfiltered SCR (thyristor) drives have a form factor (FF) of 1.40. Pure DC, as from a battery, has a form factor of 1.0. Filtered thyristor and pulse width modulated drives often have a form factor of 1.05. Frame: Standardized motor mounting and shaft dimensions as established by NEMA or IEC. Frequency: Alternating electric current frequency is an expression of how often a complete cycle occurs. Cycles per second describe how many complete cycles occur in a given time increment. Hertz (hz) has been adopted to describe cycles per second so that time as well as number of cycles is specified. The standard power supply in North America is 60 hz. Most of the rest of the world has 50 hz power. Full Load Amperes (FLA): Line current (amperage) drawn by a motor when operating at rated load and voltage on motor nameplate. Important for proper wire size selection, and motor starter or drive selection. Also called full load current. Full Load Torque: The torque a motor produces at its rated horsepower and full-load speed. Fuse: A piece of metal, connected in the circuit to be protected, that melts and interrupts the circuit when excess current flows. Generator: Any machine that converts mechanical energy into electrical energy. Grounded Circuit: • An electrical circuit coupled to earth ground to establish a reference point. • A malfunction caused by insulation breakdown, allowing current flow to ground rather than through the intended circuit. Hertz: Frequency, in cycles per second, of AC power; usually 60 hz in North America, 50 hz in the rest of the world. Named after H. R. Hertz, the German scientist who discovered electrical oscillations. High Voltage Test: Application of a voltage greater than the working voltage to test the adequacy of motor insulation; often referred to as high potential test or “hi-pot.” Horsepower: A measure of the rate of work. 33,000 pounds lifted one foot in one minute, or 550 pounds lifted one foot in one second. Exactly 746 watts of electrical power equals one horsepower. Torque and RPM may be used in relating to the horsepower of a motor. For fractional horsepower motors, the following formula may be used. HP = T (in.-oz) x 9.917 x N x 107 where, HP = horsepower T = Torque N = revolutions per minute Hysteresis: The lagging of magnetism in a magnetic metal, behind the magnetizing flux which produces it. IEC (International Electrotechnical Commission): The worldwide organization that promotes international unification of standards or norms. Its formal decisions on technical matters express, as nearly as possible, an international consensus. IGBT: Stands for isolated gate bipolar transistor. The most common and fastest-acting semiconductor switch used in pulse width modulated (PWM) AC drives. Impedance: The total opposition in an electric circuit to the flow of an alternating current. Expressed in ohms. Induction Motor: The simplest and most rugged electric motor, it consists of a wound stator and a rotor assembly. The AC induction motor is named because the electric current flowing in its secondary member (the rotor) is induced by the alternating current flowing in its primary member (the stator). The power supply is connected only to the stator. The combined electromagnetic effects of the two currents produce the force to create rotation. Insulation: In motors, classified by maximum allowable operating temperature. NEMA classifications include: Class A = 105°C, Class B = 130°C, Class F = 155°C and Class H = 180°C. Input Horsepower: The power applied to the input shaft of a gear reducer. The input horsepower rating of a reducer is the maximum horsepower the reducer can safely handle. Integral Horsepower Motor: A motor rated one horsepower or larger at 1800 RPM. By NEMA definitions, this is any motor having a three digit frame number, for example, 143T. Inverter: An electronic device that changes direct current to alternating current; in common usage, an AC drive. Kilowatt: A unit of power equal to 1000 watts and approximately equal to 1.34 horsepower. Load: The work required of a motor to drive attached equipment. Expressed in horsepower or torque at a certain motor speed. Locked Rotor Current: Measured current with the rotor locked and with rated voltage and frequency applied to the motor. Locked Rotor Torque: Measured torque with the rotor locked and with rated voltage and frequency applied to the motor. Magnetic Polarity: Distinguishes the location of north and south poles of a magnet. Magnetic lines of force emanate from the north pole of a magnet and terminate at the south pole. Mechanical Rating: The maximum power or torque a gear reducer can transmit. Many industrial reducers have a safety margin equal to 200% or more of their mechanical rating, allowing momentary overloads during start-up or other transient overloads. Motor Types: Classified by operating characteristics and/or type of power required. The AC induction motor is the most common. There are several kinds of AC (alternating current) induction motors, including, for single phase operation: shaded pole, permanent split capacitor (PSC), split phase, capacitor start/induction run and capacitor start/capacitor run. Polyphase or three-phase motors are used in larger applications. Direct current (DC) motors are also common in industry as are gearmotors, brakemotors and other types. Mounting: The most common motor mounts include: rigid base, resilient base C face or D flange, and extended through bolts. Gear reducers are similarly base-mounted, flange-mounted, or shaft-mounted. National Electric Code (NEC): A safety code regarding the use of electricity. The NEC is sponsored by the National Fire Protection Institute. It is also used by insurance inspectors and by many government bodies regulating building codes. NEMA (National Electrical Manufacturers Association): A non-profit trade organization, supported by manufacturers of electrical apparatus and supplies in the United States. Its standards alleviate misunderstanding and help buyers select the proper products. NEMA standards for motors cover frame sizes and dimensions, horsepower ratings, service factors, temperature rises and various performance characteristics. Open Circuit: A break in an electrical circuit that prevents normal current flow. Output Horsepower: The amount of horsepower available at the output shaft of a gear reducer. Output horsepower is always less than the input horsepower due to the efficiency of the reducer. Output Shaft: The shaft of a speed reducer assembly that is connected to the load. This may also be called the drive shaft or the slow speed shaft. Overhung Load: A force applied at right angles to a shaft beyond the shaft’s outermost bearing. This shaft-bending load must be supported by the bearing. Phase: The number of individual voltages applied to an AC motor. A single-phase motor has one voltage in the shape of a sine wave applied to it. A three-phase motor has three individual voltages applied to it. The three phases are at 120 degrees with respect to each other so that peaks of voltage occur at even time intervals to balance the power received and delivered by the motor throughout its 360 degrees of rotation. Plugging: A method of braking a motor that involves applying partial or full voltage in reverse to bring the motor to zero speed. Polarity: As applied to electric circuits, polarity indicates which terminal is positive and which is negative. As applied to magnets, it indicates which pole is north and which pole is south. Poles: Magnetic devices set up inside the motor by the placement and connection of the windings. Divide the number of poles into 7200 to determine the motor’s normal speed. For example, 7200 divided by 2 poles equals 3600 RPM. Power Factor: The ratio of “apparent power” (expressed in kVA) and true or “real power” (expressed in kW). Power Factor = Real Power Apparent Power Apparent power is calculated by a formula involving the “real power,” that which is supplied by the power system to actually turn the motor, and “reactive power,” which is used strictly to develop a magnetic field within the motor. Electric utilities prefer power factors as close to 100% as possible, and sometimes charge penalties for power factors below 90%. Power factor is often improved or “corrected” using capacitors. Power factor does not necessarily relate to motor efficiency, but is a component of total energy consumption. Prime Mover: In industry, the prime mover is most often an electric motor. Occasionally engines, hydraulic or air motors are used. Special application considerations are called for when other than an electric motor is the prime mover. Pull Out Torque: Also called breakdown torque or maximum torque, this is the maximum torque a motor can deliver without stalling. Pull Up Torque: The minimum torque delivered by a motor between zero and the rated RPM, equal to the maximum load a motor can accelerate to rated RPM. Pulse Width Modulation: Abbreviated PWM, the most common frequency synthesizing system in AC drives; also used in some DC drives for voltage control. Reactance: The opposition to a flow of current other than pure resistance. Inductive reactance is the opposition to change of current in an inductance (coil of wire). Capacitive reactance is the opposition to change of voltage in a capacitor. Rectifier: A device or circuit for changing alternating current (AC) to direct current (DC). Regenerative Drive: A drive that allows a motor to provide both motoring and braking torque. Most common with DC drives. Relay: A device having two separate circuits, it is constructed so that a small current in one of the circuits controls a large current in the other circuit. A motor starting relay opens or closes the starting circuit under predetermined electrical conditions in the main circuit (run winding). Reluctance: The characteristics of a magnetic field which resist the flow of magnetic lines of force through it. Resistor: A device that resists the flow of electrical current for the purpose of operation, protection or control. There are two types of resistors - fixed and variable. A fixed resistor has a fixed value of ohms while a variable resistor is adjustable. Rotation: The direction in which a shaft turns is either clockwise (CW) or counter clockwise (CCW). When specifying rotation, also state if viewed from the shaft or opposite shaft end of motor. Rotor: The rotating component of an induction AC motor. It is typically constructed of a laminated, cylindrical iron core with slots for cast-aluminum conductors. Short-circuiting end rings complete the “squirrel cage,” which rotates when the moving magnetic field induces a current in the shorted conductors. SCR Drive: Named after the silicon controlled rectifiers that are at the heart of these controls, an SCR drive is the most common type of general purpose drive for direct current motors. Self-Locking: The inability of a gear reducer to be driven backwards by its load. Most general purpose reducers are not self-locking. Service Factor for Gearing: A method of adjusting a reducer’s load carrying characteristics to reflect the application’s load characteristics. AGMA (American Gear Manufacturers Association) has established standardized service factor information. Service Factor for Motors: A measure of the overload capacity built into a motor. A 1.15 SF means the motor can deliver 15% more than the rated horsepower without injurious overheating. A 1.0 SF motor should not be loaded beyond its rated horsepower. Service factors will vary for different horsepower motors and for different speeds. Short Circuit: A fault or defect in a winding causing part of the normal electrical circuit to be bypassed, frequently resulting in overheating of the winding and burnout. Slip: The difference between RPM of the rotating magnetic field and RPM of the rotor in an induction motor. Slip is expressed in percentage and may be calculated by the following formula: Speed Regulation: In adjustable speed drive systems, speed regulation measures the motor and control’s ability to maintain a constant preset speed despite changes in load from zero to 100%. It is expressed as a percentage of the drive system’s rated full load speed. Stator: The fixed part of an AC motor, consisting of copper windings within steel laminations. Temperature Rise: The amount by which a motor, operating under rated conditions, is hotter than its surrounding ambient temperature. Temperature Tests: These determine the temperature of certain parts of a motor, above the ambient temperature, while operating under specific environmental conditions. Thermal Protector: A device, sensitive to current and heat, which protects the motor against overheating due to overload or failure to start. Basic types include automatic rest, manual reset and resistance temperature detectors. Thermal Rating: The power or torque a gear reducer can transmit continuously. This rating is based upon the reducer’s ability to dissipate the heat caused by friction. Thermostat: A protector, which is temperature-sensing only, that is mounted on the stator winding. Two leads from the device must be connected to a control circuit, which initiates corrective action. The customer must specify if the thermostats are to be normally closed or normally open. Thermocouple: A pair of dissimilar conductors joined to produce a thermoelectric effect and used to accurately determine temperature. Thermocouples are used in laboratory testing of motors to determine the internal temperature of the motor winding. Thrust Load: Force imposed on a shaft parallel to a shaft’s axis. Thrust loads are often induced by the driven machine. Be sure the thrust load rating of a gear reducer is sufficient so that its shafts and bearings can absorb the load without premature failure. Torque: The turning effort or force applied to a shaft, usually expressed in inch-pounds or inch-ounces for fractional and sub-fractional HP motors. Starting Torque: Force produced by a motor as it begins to turn from standstill and accelerate (sometimes called locked rotor torque). Full-Load Torque: The force produced by a motor running at rated full load speed at rated horsepower. Breakdown Torque: The maximum torque a motor will develop under increasing load conditions without an abrupt drop in speed and power. Sometimes called pull-out torque. Pull-Up Torque: The minimum torque delivered by a motor between zero and the rated RPM, equal to the maximum load a motor can accelerate to rated RPM. Transformer: Used to isolate line voltage from a circuit or to change voltage and current to lower or higher values. Constructed of primary and secondary windings around a common magnetic core. Underwriters Laboratories (UL): Independent United States testing organization that sets safety standards for motors and other electrical equipment. Vector Drive: An AC drive with enhanced processing capability that provides positioning accuracy and fast response to speed and torque changes. Often used with feedback devices in a closed-loop system. Voltage: A unit of electromotive force that, when applied to conductors, will produce current in the conductors. Watt: The amount of power required to maintain a current of 1 ampere at a pressure of one volt when the two are in phase with each other. One horsepower is equal to 746 watts. Winding: Typically refers to the process of wrapping coils of copper wire around a core. In an AC induction motor, the primary winding is a stator consisting of wire coils inserted into slots within steel laminations. The secondary winding of an AC induction motor is usually not a winding at all, but rather a cast rotor assembly. In a permanent magnet DC motor, the winding is the rotating armature. Motor-driven-countdown-timer Delay-timer-for-motor-or-pump How-to-wire-motor-control-contactor Motor-driven-countdown-timer How-to-control-motor-with-two-switches wire-size-for-motor calculate-inrush-for-3-phase-motor |
 Outdoor motors, pumps, equipment, metal subpanels, boxes etc must be connected to main panel ground wire, and can be bonded to a separate ground rod as back up. Do not touch metal electrical equipment if power is ON. Use ohmmeter to verify resistance between earth and motor frame is less than 0.5 Ω Resource Why you need ground wire |
 Inspect the ground connection at ground rod  If the ground wire is disconnected from
ground rod, DO NOT reconnect the ground unless main breaker is
de-energized.Do not touch or remove ground rod. |
 Volts x Amps = Watts Amps = Watts divided by Volts Typical motor starting currents of 6 to 8 times normal running current when starting. |
Motor amp draw Buy: AO smith / Century / motors at Amazon Dayton motors at Amazon Electric motors at Amazon Draft inducer blowers for gas appliance + water heater Water pumps at Amazon Wet dry vacs Resources: Motors can run 10% more or 10% less than rated voltage AO Smith motors with troubleshoot and wiring .pdf AO Smith motor wiring Magnetec motors is AO Smith, AO Smith motors are now Century Motor troubleshooting/ pdf Motor troubleshoot 2/ pdf Timer for 2-speed motor Repair and wire motors .pdf Basic motor wiring illustration .jpg Reverse motor .pdf Hayward pool equipment error codes Swimming pool replacement motors and identification The motor doctor Dayton motor guide/ pdf Control motor with 2 switches Dayton Motors: Dayton Manufacturing is owned by WW Grainger. Contact Grainger. Always connect ground wire. |
| " Current capacity must be adequate enough to maintain
rated voltage at the motor terminals under all conditions. If it’s too
high, contact the local utility. If it’s too low check for overloaded circuits, loose connections or wire of the wrong gauge" |
More than 3300 feet above sea level, use next higher
horsepower. Motor must be grounded. Test that ground is connected. Turn power off before touching motor. Incorrect voltage at motor will cause motor to overheat. Check wire size. Motors are hot to touch. Provide ample circulation around motor. |
  |
Horsepower
/ wire size / distance Motor horsepower and wire size for 115Volt and 240V Horsepower = watts ÷ 746 Resource: How to wire subpanel For example: 1-1⁄2 Hp motor at 115 volts over a distance of 150 feet, use #8 wire. If the motor can be installed to operate on 230 volts, #12 wire should be sufficient for a 150 foot distance |
 Larger image Horsepower / wire size / distance |
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Length of wire/ amp draw Use larger wire and breaker with longer distance |
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Single-phase/
3-phase Wire and Breaker size chart |
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Single-phase/ 3-phase Amp load by Kilowatt |
 Inrush
is the amp consumption of a
motor during start-up. Motors are inductive. Inductive loads consume more amps when starting. Once the motor has started, the amperage drops to normal. Each motor has a label with a locked-rotor code that is needed for the calculation. Use chart below. The locked rotor code is a letter A-V, with each letter corresponding to a range of KVA per HP (horsepower). KVA is kilo volt amps. Volt amps is watts. So KVA is a measure of watts or power or KW ... how much power the motor delivers. The locked rotor code is used to calculate the inrush or amperage needed for that specific motor during start up. The example problem on left shows 50 HP 3-phase motor with locked-rotor H, which has KVA range of 6.3-7.1 KVA per HP. The KVA range is plugged into the formula: 7.1 x 50 HP = 355 KWA or KW at start up 355 KW = 355,000 watts P (power or watts) = E (volts) x I (amperage) x .173 1.73 is the square root of 3, used for 3-phase calculations. 355,000 watts = 480 volts x I (unknown amps) x 1.73. Solve for amps: I = 355,000 ÷ 480 x 1.73  Residential single-phase motors also have inrush. This is generally not an issue when calculating household wire and breaker size since the HP rating is relatively small, start-up is brief, and circuit breaker doesn't react fast enough to trip with the small surge of amperage (heat) on the wire. However large swimming pool motors, and other application that use 3-5 HP motors should have oversized wire and breaker to supply ample electricity for start. Resources: Locked rotor KVA nameplate rating: Calculate inrush .pdf Difference between single-phase and 3-phase Color code for wire |
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 Household NM-B Wires are color-coded so inspectors/ electricians can easily identify which wire is used during construction Damp- wet locations: For direct burial underfoot, in contact with damp soil ... or for other damp locations ... use UF-B wire ... or use plastic conduit. UF-B wire can be difficult to strip back for wiring.  |
Match
wire size and breaker amp rating If your home was wired by professional electrician who pulled permits, then circuit breaker and wire size will match. If manufactured home or travel trailer has not been altered by homeowner then breaker and wire size will match. Safe maximum of amp draw on a breaker is 80% rated value of breaker. Look at label on each load (TV, refrigerator, box fan etc). Add up total watt load on circuit. Divide the watts by the voltage on line = amps. If breaker is oversized for wire... fire danger Breaker can let too much electricity travel through the wire. Wire can overheat and cause fire. Call electrician if you suspect wiring is not correct, Absolute electrocution danger when removing cover off main panel. More information below. Main breaker terminals are still Hot when main breaker is turned off. Use 600 volt solid copper wire only Do not use stranded wire inside main breaker box or any permanent box. Stranded wire can be used for connectors and plugs. Do not use extension cord for permanent household wiring Extension cords are used for connectors and plugs only. Read more about uses for extension cords Buy: Wire wire at Amazon Resource: How to replace circuit breaker |
 |
Match
breaker to
voltage that shows on appliance label 3-phase breakers are used for commercial service panels Code says: Use connected/ double-pole breaker Against code: Use 2 single breakers to supply 240 volt, unless the switches are connected and rated for same amps If double breaker is rated for 30 amp, then BOTH sides of the breaker are each 30 amp (not 15 amp each) Power is doubled with 240 volt vs 120 volt, amps are not halved Resource: How to replace circuit breaker 3-phase wiring |
 |
Circuit
breaker and wire size must match Chart on left shows that 30 amp breaker matches 10 gauge copper wire. Do not use aluminum wire. Copper wire is safe. Aluminum wire expands when electricity travels through wire. Expansion causes loose connections and fire hazard. Rating for short lengths household NM-B and UF-B Resources: Larger image with wire types, temperature, long length Maximum wattage for household NM-B and DU-F wires Wire diameter, weight, resistance |
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How
to figure correct size wire and breaker Use chart on left to select wire and breaker (for short lengths of wire) Use the 80% rule when calculating Capacity. wattage shown on chart shows the 80% rule. When wires and breakers operate at 100%, they get warm. Warm wires mean amp loss and potential fire hazard. Warm breaker means that breaker will not last as long, and busbar can be damaged by heat (over period of time) 14 ga wire ++ rated for 120 Volts x 15 Amp = 1800 Watts x 80% = 1440 Watts safe maximum 12 ga wire ++ rated for 120 Volts x 20 Amps = 2400 Watts x 80% = 1920 Watts safe maximum 10 ga wire ++ rated for 240 Volts x 30 Amps = 7200 Watts x 80% = 5760 Watts safe maximum |
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Longer
distance requires larger breaker and larger wire Look at label to find watt rating of appliance, or motor or tool measure distance between appliance and main breaker panel Use chart to select larger wire when needed Volts x amps = watts Watts divided by volts = amps Volts squared divided by watts = ohms Resources: Electrical formulas Larger image with wire types, temperature, long length Maximum wattage for household NM-B and DU-F wires Wire diameter, weight, resistance |
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Circuit
breaker resources Water heater is tripping breaker How to replace circuit breaker How to wire gfci Can AC breaker be used for DC breaker How to reset circuit breaker Not enough space for circuit breakers/ use tandem Circuit breakers How to install subpanel Why you need ground wire See inside breaker box How to wire safety switch How to wire whole house surge protector Figure volts amps and watts Figure correct wire and breaker Types of surge protection |
 Larger imageUse in-line fuse when connecting 2 different gauge wires Illustration shows smaller 12-2 cable connected to larger 10-3 cable. The 10 gauge wire carries 240 volt plus a Neutral wire, and is protected by 30 amp breaker The amp draw on 30 amp breaker is too large for 12 gauge wire. 12 gauge wire should have 20 amp breaker. Connect
smaller
12 gauge wire to 10 gauge wire using twist on wire connector. All
connections must be inside electrically rated enclosed box with cover.
Use fuseholder with 20 amp fuse.Fuse will protect entire length of 12 gauge wire. Connect fuse to Hot wire. Never put fuse on Neutral ... the Neutral wire must never be switched off, and must run continuous throughout installation. If the 12 gauge wire is wired for 240V, instead of 120V shown in illustration, then fuses can be added to both hot wires. Always make connections inside a box with cover Buy: Panel mount fuse holders at Amazon ANL fuseholder Buy fuseholders Din rail fuseholder 10 x 38 mm fuse Electrical terminals Solder guns Resource: See fuseholder |
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 4500 watt and 5500 watt water heaters should connect to 30 amp breaker and 10 gauge wire. |
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safe maximum for water heater circuit If residential water heater is connected to 20 amp breaker and 12 gauge wire, then overheating problem occurs over time. Circuit breaker will not last as long, and damage can occur to busbar. Resource: See basic water heater circuit How to replace circuit breaker 20 amp breaker is subject to 80% safe-maximum rule. 20 amp circuit breaker x .8 = 16 amps. So safe maximum for 20 amp breaker is 16 amps. 240Volt 4500 watt water heater draws 18.75 amps. And 5500 watt water heater draws 22.91 amps. So 20 amp breaker with 12 gauge wire is rated too small for most water heaters. Over time the breaker is getting warm, and is more likely to get hot and fail. Recommended that all water heaters be connected to 30 amp breaker and 10 gauge wire. Safe maximum for 30 amp breaker x .8 = 24 amps. Safe maximum for 10 gauge wire at 240volts is 5670 watts See chart 30 amp breaker and 10 gauge wire run cooler, with less heat loss and more efficiency. Circuit breaker and main box last longer with less chance for heat damage. Resource: Figure Volts Amps Watts for water heater |
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Household
Main panel 120 volt and 240 volt This is called single-phase electric power. Phasing is determined by the power company. - Each 120 volt circuit can include up to 12 outlets, and supply power to lights inside a room. - Generally each 120 volt circuit sends power to one area of home. This is because the wire leaves breaker box and goes to first junction box inside a room. From the junction box, the wire splits off and goes to each individual box, jumping from box to box until the final box is reached. So each box will have 1 black hot wire, 1 white neutral wire, and 1 ground wire that connect back to main breaker box. - Some circuit breakers are dedicated to 1 specific appliance. For example the kitchen microwave is usually wired to 1 circuit breaker and no other outlets or lights are connected to that breaker. This is because microwave draws so much amperage. That is called dedicated circuit, and dedicated breaker. - Each 240 volt circuit is usually dedicated to one appliance. For example electric water heater is connected to 1 240 volt breaker. The electric dryer is connected to another 240 volt breaker. The heat/AC is connected to another 240 volt circuit breaker, and so on. Resources: See inside main breaker box How to replace circuit breaker How to install subpanel Figure volts amps watts for electric water heater How to wire GFCI How to wire Arc fault breaker |
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What is 3-phase electric: power plant to end
user
How to wire 3-phase timer 3-phase water heater |
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