Full Load current calculation of AC and DC machine:
What is Full Load Current:
Full Load Current is nothing but a maximum allowable current. The input current to the machine exceeds the full load current means, the electrical machine may get damage. Due to the excess current flow, the machine produces additional heat (Because of P=I^{2} * R)., This may lead to damages to the insulation or winding of the electrical equipment. Hence, Operating a machine below full load current increases the life span of the electrical equipment.
AC Loads (Alternating current) :
Full Load current calculation 3 Phase Motor:
In most of the Threephase systems, electricity consumption happens through star and delta connection. The input power (P) to the system is the same, irrespective of the connection.
Power in KW (Kilowatts)
V= Voltage +/ 10 % in Volts
I= Full load current in Amps
Cos pi = power factor
Three Phase Power P = 3 V*I* Cos pi
KW = output power in Watts……. All are given at the nameplate details.
As we said, the full load current of the threephase system is depending on the type of connection.
Here
Iph => Phase Current
Iline => Line Current
For Star Connection the Full Load Current Iline is equal to Iph
Iph = Iline
For Delta Connection the Full Load Current Iline is equal to 1.732 times of Iph
Iph/1.732 = Iline
Hence Three Phase full load current I is equal to
I= P/(1.732*V*Cos pi)
Full Load current calculation Singlephase Motor:
P = V * I * Cos pi
V= Voltage +/ 10 % in Volts
I= Full load current in Amps
Cos pi = power factor
KW = output power in Watts……. All are given at the motor’s nameplate details.

I =P / V * cos pi Amps
Full Load current calculation Threephase Heater coil:
Power formula KW
V= Voltage
I= Full load current in Amps
KW = output power in Watts……. All are given on the heater’s plate details.

Iinput =P / 1.732 * V * I Amps.
Full Load current calculation Single phase heaters:
Power formula KW
V= Voltage
I= Full load current in Amps
KW = output power in Watts……. All are given on the heater’s plate details.

I = V X I Amps
Calculate through resistance:
 Measure the resistance R of the heater coil using multi meter.
 Use this formula
P = I^2 * R
 I = square root of (P/R)
Also see: How to Calculate Voltage Drop
Full Load current calculation DC machine (DC Motor & DC generator):
DC => Direct Current
P= V X I
 I = P/V amps, Where
V = E ± Ia Ra ± Is Rsh + brushes drop (shunt machine)
V = E ± Ia (Ra + Rsh) + brushes drop (series machine)
V = Supply Voltage
E = back emf
 Also see: Difference Between Voltage and EMF
Ia = armature current
Ra = armature resistance
Is = Field current
Rsh = Field resistance
Back EMF e = (pi * N * P * Z / 60 A)
Pi= Magnetic Flux
P = number of poles
Z = number of conductors
A = number of parallel paths
P = A for lab winding
A= 2 for wave winding
Myths About Full Load Current:
 Full Load Current For aluminum cable is o.8 per square meter
 For Copper Cable is 1.2 per square meter
 3 phase 415V, at 0.8 pf, 1 Hp motor full load current = 1.3 Amps.
 1 Phase 230V, at 0.8 pf, 1 Hp motor full load current = 4 Amps.