sophiecentaur said:
What bothers me is the appliance lead is not protected for a fault on the appliance because it is upstream of the appliance and can be supplied with far too much current from upstream.
Under the right conditions an overcurrent device is totally capable of protecting conductors upstream of the device.
Let that sink in for a second. Yes I realize it goes completely against the basics of circuit design. Nevertheless it is true.
Short circuits, ground faults, and overloads are all types of overcurrent condition. Should a short circuit or ground fault occur ahead of, or on the line side of an overcurrent device, the device will not actuate. Why? Because the circuit current never flows as far as the OCP, it takes a path back to the source without ever reaching it.
With me so far? Good. Now an overload condition is a special case. The circuit is operating pretty much as it is designed to, except the current draw is in excess of its design. So let's say an appliance is designed to run at 7 amps. It is connected to its supply branch circuit through a flexible cord, let's say it is 16 AWG which will supply 7 amps quite comfortably under normal conditons and in fact is only at about two thirds its rated capacity per NEC. But let's say this is some sort of motor load, maybe a fish tank pump or something, anyway it has a low volt control circuit supplied through a small power limited transformer. The control circuit passes through a thermal overload device set at 9 amps.
Now, somehow, your favorite goldfish manages to get the filter screen on the pump loose and swims into the impeller. Poor goldie, but you've got a bigger problem now as he has jammed your pump and intends to burn the whole residence down around you. The no longer turning motor is acting as a dead short, drawing 20 amps as it sits in a locked rotor condition. The branch circuit protection, back in the panel where the circuit originates, does not see a problem as the 12AWG wire is sized properly to carry this current safely for hours. But the cord supplying the pump, with only half this safe capacity, is on its way to temperatures well in excess of its insulation rating. This is not good, and is not acceptable by code for obvious reasons.
Lucky for you the designers of the pump system were smarter than your goldfish. They knew that even though the pump would almost certainly be supplied by a circuit capable of delivering current in excess of the cord's rating, should anything catastrophic happen to the pump which would leave it in a locked rotor condition, the heat created would trip the thermal overload and open the circuit. With the hot conductor to the motor broken, the current flow stops and the cord cools down; even though the cord was upstream of the overload relay, by virtue of breaking the circuit the overload has protected the cord.
As stated in my previous post, branch circuit devices at the panel would under most short circuit and ground fault conditions clear the circuit of power before any major damage could be done to the conductors. Yes, this sort of protection needs to be upstream, or ahead of, the potential fault. But overload protection is special, just as overloads are a special sort of overcurrent condition. I once saw a room full of 60-80 electricians, many of whom had more years in the field than myself, have this concept spelled out to them as a number of them sat in disbelief, recalling what they had been taught years ago about how OCP had to be located upstream of a fault. The instructor, who had 40+ years in just about every respect of the field as well as a master's degree in teaching, did a good job of illuminating his point to many who were resistant to the idea. This is a situation seen very often not just in appliances but also larger motor loads as well as things like welders, elevators, and many other applications.
The code is your friend, it has all the answers, if you can understand what it is telling you the power you wield is almost limitless.