How To Size A Cable Correctly Step-By-Step (Comprehensive Guide)
How To Size A Cable Correctly Step-By-Step (Comprehensive Guide)
How To Size A Cable Correctly Step-By-Step (Comprehensive Guide)
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cable per the NEC. All roads lead to Rome and all those questions above (15) and below (100) lead to the same
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Yes, This comes up in the ordering process, but most of the time it happens during the initial estimation of a new
construction project when sizing a cable is most important.
Across the United States at any given moment there are thousands of hard-working electrical construction
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From New York to Los Angeles, from Houston Texas to the Motor City, Detroit Michigan and everywhere in between
there is someone just like you trying to figure out the same thing you are right now.
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How the heck do I make sure this cable is the right size
per the NEC
(http://en.wikipedia.org/wiki/National_Electrical_Code)?
We have compiled information here for you from numerous electrical resources in the area of electrical code including
Paul Abernathy (http://www.linkedin.com/in/paulabernathy/) and his Electrical Code Academy
(http://www.electricalcodeacademy.com/), Mike Holts Forum (http://www.mikeholt.com), EC&M Magazine
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Continuing on Paul’s take above, consider this, the National Electrical Code (http://www.nfpa.org/NEC) requirements
for cable sizing/conductor sizing (http://www.ecmag.com/section/codes-standards/sizing-conductors-part-xxi) and
over-current protection have always been fairly confusing and complex. This is why it take a 2 hour appointment to
REALLY cover variables like Paul did in his video. We will try to shorten that up so you can get the point of how to size
a cable within 15 to 20 minutes (Hopefully).
1. Continuous loads
2. Terminal temperature ratings
3. Conductor insulation
4. Conductor ampacity
5. Conductor bundling
6. Ambient temperature
7. Special application
This is in accordance with their ampacities as specified in 310.15. Section 240.4(A) through (G) contains rules that
modify the general requirement and permit conductors to be protected in a manner other than their ampacities from
310.15, including:
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Cable Size Selection Chart
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Step 1 – Size the overcurrent device in accordance with 215.3. The feeder overcurrent device must be sized not less
than 125% of 184A, 184A x 125% = 230A. According to 240.6(A) we must select a minimum 250A overcurrent device.
Step 2 – Select the conductor to comply with 215.2, which requires the feeder conductor to be sized no less than 125%
of the continuous load, 184A x 125% = 230A. We must select the conductor according to the 75°C temperature rating
of the panelboards terminals [110.14(C)] – 4/0 THHN has a rating of 230A at 75°C will meet this requirement.
Step 3 – Verify the conductors selected in Step 2 is properly protected against overcurrent in accordance with 240.4.
The 4/0 AWG conductor from Step 2 is rated 230A at 75°C, it is permitted to be protected by a 250A protection device
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in accordance with the “the next size up rule” of 240.4(B).
A key concept in conductor sizing is understanding the definition of ampacity. The ampacity of a conductor is the
amount of current the conductor can carry continuously under specific conditions of use [Art. 100 definition]. The
ampacity of a conductor is not what size breaker can be used to protect the wire; it is simply the amount of current the
conductor can carry. It is important to recognize this subtlety.
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Use the conductor ampacity as listed in Table 310.16, and apply temperature adjustment factors based on the
insulation rating of the conductor. Do not base conductor ampacity adjustment on the temperature terminal ratings
discussed in 110.14(C). Understand that the location (wet, dry, or damp) influences which column ampacity of Table
310.16 to use. You can find this information in Table 310.13(A). For example, notice THHW is a 90°C conductor in a
dry location, but it’s a 75°C conductor in a wet location.
10 THHN = 40A × 0.91 = 36.40A. This is too small for the 40A load.
Table 310.16 ampacity for 8 THHN is 55A at 90°C in a dry location: Use the THHN 90°C column.
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The conductor must have an ampacity of at least 40A, after applying the ambient temperature correction factor, in
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order to carry the load. In this example, the 8 THHN/THWN has sufficient ampacity after correction in either a wet or
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with dual-rated insulation types, and use the column that corresponds to the location. In addition, keep in
mind that a conductor with a “-2” after its insulation, such as THHN/THWN-2, is rated 90°C in a wet, dry, or damp
location[Table 310.13(A)].
What if you have conductors installed in raceways exposed to direct sunlight on or above rooftops? In such cases, add
the ambient temperature adjustment in Table 310.15(B)(2)(c) to the outdoor ambient temperature when applying
ampacity adjustment correction factors contained in Table 310.16.
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When conductors are bundled together, they lose some of their ability to dissipate heat. In the NEC, the allowable
ampacity starts dropping when four or more current-carrying conductors are bundled together for more than 24
inches [310.15(B)(2)(a)] (Fig. 2).
Be aware that there are five exceptions described in 310.15(B)(2)(a), one of which is for AC or MC cable, which allows
up to 20 current-carrying conductors in 12 AWG, 2 or 3 conductor cables without having to adjust the ampacity.
If the ambient temperature is anything but 86°F — and more than three current-carrying conductors are bundled
together — adjust the ampacity (listed in Table 310.16) for both conditions.
To make that cable sizing adjustment, multiply these
three numbers together:
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To make that cable sizing adjustment, multiply these three numbers together:
Always remember that the higher insulation temperature rating of 90°C rated conductors provides a greater conductor
ampacity for use in ampacity adjustment, even though you size those conductors based on the column that
corresponds to the temperature listing of the terminals [110.14 (C)(1)]. When correcting or adjusting conductor
ampacity, use the temperature insulation rating of the conductor as listed in Table 310.16, not the temperature rating
of the terminal [110.14(C)].
If a single length of conductor has two ampacities, use the lower ampacity for the entire circuit [310.15(A)(2)]. An
exception applies: If that portion of the conductor with reduced ampacity is not longer than 10 feet and is not longer
than 10% of the length of the part of the circuit with the higher ampacity, then you can use the higher ampacity for
the entire circuit [310.15(A(2) Ex] (Fig. 3 on page 46).
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NEC Table 310.15 B 2 a How to size a cable 1XTech, Cable sizing with Current-carrying
conductors
Grounding and bonding conductors [310.15(B)(5)]Grounding and bonding conductors are never considered
current carrying. Don’t count grounding and bonding conductors when adjusting conductor ampacity for the
effects of conductor bundling [310.15(B)(5)]. They do, however, occupy space in the raceway and are included in
raceway fill calculations (see Chapter 9, Table 1, Note 3), so you are accounting for their presence. You just aren’t
counting them as current-carrying conductors.
2-wire circuits neutral and ungrounded conductors of a 2-wire circuit are considered current carrying.
Neutral conductor — unbalanced loads [310.15(B)(4)(a)]A neutral conductor that carries only the unbalanced
current from other conductors of the same circuit is not considered a current-carrying conductor (Fig. 4 on page
48).
Neutral conductor — unbalanced 3-wire wye circuit [310.15(B)(4)(b)]The neutral conductor of a 3-wire circuit of
a 4-wire, 3-phase, wye-connected system carries about the same current as the line-to-neutral load currents of
the other conductors. As a result, it’s considered a current-carrying conductor.
Neutral conductor — nonlinear loads [310.15(B)(4)(c)]The neutral conductor for a 4-wire, 3-phase wye circuit is
considered a current-carrying conductor where more than 50% of the load consists of nonlinear loads (Fig. 5).
Nonlinear loads supplied by a 4-wire, 3-phase, 120/208V or 277/480V wye-connected system can produce unwanted
and potentially hazardous harmonic currents. Odd triplen harmonic currents (3rd, 9th, 15th, etc.) can add on the
neutral conductor. To prevent fire or equipment damage from excessive harmonic neutral current, consider increasing
the size of the neutral conductor or installing a separate neutral for each phase. See 210.4(a) FPN, 220.61(C) FPN No.
2, and 450.3 FPN No. 2.
The last two items are where things can get dicey if you don’t do your homework. Find out what the ambient
temperature will be along the entire length of each conductor. Such things as cable routing [see the example in
Appendix D3(a)] and ventilation can change ambient temperature considerably, so take the time to review the entire
installation — not just the electrical drawings.
If you correctly anticipate the ambient temperatures and perform the necessary ampacity adjustments, then you’ll
meet the NEC minimums for conductor sizing. From there, you can decide whether to allow for other considerations in
making a final determination of conductor size.
Dunwoody College’s Elftmann Student Success Center invites you to enhance your learning of wire resistance and
voltage drop. This will help you advance your Traction power cable calculations.
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