For a metal enclosure to stay safe during a fault, enough current must flow back through the equipment grounding conductor to trip the breaker instantly. This calculator builds the ground-fault loop impedance from the phase and grounding conductors, derives the prospective fault current, and checks it against the breaker’s instantaneous trip threshold per NEC 250.4(A)(5).
How it works
The fault current is limited by the round-trip loop impedance:
Z_loop = R_phase + R_egc + Z_source
I_fault = V_line-to-ground / Z_loop
trip threshold = instantaneous multiple × OCPD rating
pass if I_fault ≥ trip threshold
Conductor resistances come from the copper DC values in NEC Chapter 9 Table 8, scaled by the one-way run length. The instantaneous multiple models the breaker’s magnetic trip, where a standard thermal-magnetic breaker picks up around 10 times its rating.
Worked example
A 20 A breaker feeds a 100 ft run of 12 AWG copper with a 12 AWG equipment grounding conductor at 120 V line-to-ground.
From NEC Chapter 9 Table 8, 12 AWG copper has a DC resistance of approximately 1.98 Ω per 1000 ft:
R_phase = 1.98 × (100 / 1000) = 0.198 Ω
R_egc = 1.98 × (100 / 1000) = 0.198 Ω
Z_source = 0.05 Ω (typical transformer secondary impedance for a small panel)
Z_loop = 0.198 + 0.198 + 0.05 = 0.446 Ω
I_fault = 120 / 0.446 ≈ 269 A
trip threshold = 10 × 20 = 200 A
Result: PASS — 269 A exceeds 200 A
Now extend the run to 400 ft with the same conductors:
R_phase = 1.98 × (400 / 1000) = 0.792 Ω
R_egc = 1.98 × (400 / 1000) = 0.792 Ω
Z_loop = 0.792 + 0.792 + 0.05 = 1.634 Ω
I_fault = 120 / 1.634 ≈ 73 A
trip threshold = 200 A
Result: FAIL — 73 A does not reach the 200 A instantaneous threshold
This is why long branch circuits need their equipment grounding conductors upsized or require GFCI/AFCI protection to clear faults at lower currents.
Common fixes for failing circuits
- Increase the EGC size. A larger equipment grounding conductor has lower resistance. The NEC allows an EGC upsized beyond Table 250.122 minimum when the circuit is long.
- Add GFCI protection. GFCI devices trip at as little as 4 to 6 mA, regardless of impedance, so a high-impedance path cannot defeat them the way it can defeat a thermal-magnetic breaker’s instantaneous element.
- Reduce the run length. Adding a sub-panel closer to the load cuts both conductor lengths and the loop impedance proportionally.
Tips and notes
Lengthen the run or shrink the grounding conductor and the loop impedance climbs until the fault current can no longer reach the trip threshold. Remember this uses DC resistance, which suits small conductors and short branch circuits; for long feeders or large conductors, switch to the full alternating-current impedance method that includes reactance.