Shop wiring

[will gilmore]

I have just moved into a new shop and I need to run wires to power some machines and welders. I have 3ph 208V at the panel. I measured the actual voltage to be 213V between phases.

Here are the machines:

Tree CNC for retrofit. 2hp 3ph spindle motor (6.2A@230V nameplate) This machine already has 30A fuses in place which I think I will keep. 5' from panel.

Bridgeport milling machine. 1.5hp 3ph spindle motor (4.4A@230V nameplate) 10' from panel.

Small shop built CNC lathe. 2hp spindle motor (6A @230V nameplate) VFD can take 1ph or 3ph. 20' from panel.

Manual lathe not yet purchased. 3hp max 3ph(10.6A@208V NEC FLA table) 25' from panel.

Miller Dynasty 350 welder 36A@208V 3ph nameplate. 30'-40' from panel.

Belt sander. 2hp 3ph (5.5A@208V nameplate). 30' from panel.

Air compressor. 7.5hp 1ph (32A@230V name plate) 65' from panel

Here are my questions:
Wires and breakers
Tree CNC - #10 THHN - 30A, 3 pole breaker.
Bridgeport - I've already wired this with #12 THHN and a 20A 3 pole breaker.
CNC Lathe - #12 THHN - 20A 2 pole or 3 pole breaker.
Manual lathe - #12 THHN - 20A 3 pole breaker.
Welder - #8 THHN - 40A breaker (Owners manual recommends 10 gauge wire with 40A time delay or 50A normal circuit breaker)
Belt sander - #12 THHN - 20A 3 pole breaker.
Air compressor - #6THHN, #6 Ground? - 50A 2pole breaker.

I would like to use two NEMA 14-50 style receptacles for the welder so I can plug it in in two places. They are rated for 50A with 3 conductors and a ground.

Should I combine any of the other circuits? For example plug the belt sander in to the welder plug or put the two lathes on one circuit. I think I need to combine at least one pair to have enough room in the panel.

What size conduit should I run? I have a hand bender for 3/4" EMT but I don't mind buying a bender for 1" or 1-1/4" EMT. Should I run everything in its own conduit, a couple bigger ones, or one big one for everything?

Should all grounds come back to panel individually or can they be daisy chained?

Wow, that is a long post. If you can contribute any help I would appreciate it.

[txcncman]

There are both national and local electrical codes that need to be met. Personally, I would always have each machine on its own circuit for safety and maintenance reasons. Yes, the more copper and disconnects and circuit breakers you buy, the more expensive it gets. But, what is expensive is liability when someone gets hurt. Also be wary of wires sizes, I have found that what is usually recommended in charts and tables is one wire size smaller than what is needed to avoid voltage drops.

[will gilmore]

Thanks for the reply. I've done all the reading I can and that's what I came up with. Any thoughts on conduit size?

[txcncman]

If I have to pull the wire myself, it better be huge. There are charts available that will tell how many wires of certain sizes can be run in various size conduit. The problem I have seen is that these charts do not allow "extra room" for pulling wire through 90 degree ells or 90 degree bends. A good rule of thumb might be when you put the desired wires into the conduit you can still easily get your thumb inside. This should leave enough "extra room".

[will gilmore]

I've come to the same conclusion about pulling. The chart says 9 #12 wires in a 1/2" EMT, yeah right. I guess I'll go 1 or 1-1/4 for the welder and air compressor and 3/4 for the other circuits.

[Al_The_Man]

Pick up a Fish Tape and Wiring Lube.
Al.

[underthetire]

Look up the nfpa code. It's usually no more than a 80 percent fill on conduit, and changes for every bend in the conduit. It speced for heat dissipation in the lines.

[will gilmore]

I've never heard anything about accounting for bends in the conduit. Do you have any more information on that?

[txcncman]

Only information I have is practical. Nothing written down. Once you get up to about #8 wire size, it does not like to bend very well. Common sense should tell you pulling 3 #8's though 1-1/2" conduit should be easier than pulling 3 #8's through 1" conduit, even though a chart (Conduit size) says you can put 9 #8's in 1" conduit.

[Al_The_Man]

This is why you need the wiring lube,
Makes wiring a cinch, you obviously need 2 people when pulling wires.
Using the lube you don't need to cut down on wire capacity for bends, especial on wide bend EMT.
Al.

[will gilmore]

Fish tape and lube it is. Thanks everyone.

[will gilmore]

One more question. I'm putting in two receptacles for the welder. I'm familiar with grounding boxes using a pig tail going to a screw in the box. What do I do with #6THHN wire. I don't think their are wire nuts that accept 4 #6 wires.