How To Size A Cable Correctly Step-By-Step (Comprehensive Guide)

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CABLE SIZING (HTTPS://1XTECHNOLOGIES.COM/CABLE-SIZING/) / CABLE TECHNICAL


HANDBOOK (HTTPS://1XTECHNOLOGIES.COM/CABLE-TECHNICAL-HANDBOOK/) / CONDUCTOR
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REFERENCES/) / NEC (HTTPS://1XTECHNOLOGIES.COM/NEC/)

How to size a Cable Correctly Step-By-Step [Comprehensive


Guide]
POSTED FEBRUARY 18, 2018 (HTTPS://1XTECHNOLOGIES.COM/HOW-TO-SIZE-A-CABLE/) 1XTECHNOLOGIES
(HTTPS://1XTECHNOLOGIES.COM/AUTHOR/1XTECHNOLOGIES/)

How to size a cable, Conductor sizing per the


[NEC] National Electrical Code Experts in the
USA
We wrote this article because every single day we are asked by electrical engineers, electrical contractors, and others in
the electrical construction field about “How to Size a Cable“.
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We aim for this to be the most comprehensive guide on how to size a cable on the web.

The Quick Answers for How to size a cable!


1. If you are looking for the quick answer to How to size a cable, scroll down to the Yellow highlighted text and find
the word “Simple” for the easy answer.
2. Furthermore, continue to the Pink text for the longer answer with the word variables!
3. Tip: Either choice, click play the SoundCloud link below and listen to Paul walk you through it if you have a little
time. Worth it!

P.S. If you aimed the long answer you may want to check out The difference between a good and bad electrician!
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How to size a cable: 1X Technologies on Soundcloud


Click the orange and white play button below to listen to this podcast on how to size a cable while you read along.

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First, these are the top 15 questions we commonly get


on How to size a cable
We have compiled our data and determined that these exact questions are asked the most frequently regarding
conductor sizing.

We listed the top 100 “How to size a cable questions” at the very bottom, you’ll have to click read more to see them if
interested.

See if any of these are exactly what lead you here, or if they are close to what you searched on how to find how to size a
cable:

1. How do we measure the correct cable size?


2. How do we determine the right size wire? 
3. how to measure power cable size?
4. how to measure a cable size?
5. how to size an electrical cable?
6. how to size armored cable?
7. how to select a cable size for particular load?
8. how to calculate size of cable?
9. how to work out a cable size?
10. how to size 3 phase cable?
11. how to size medium voltage cable?
12. how to size high voltage cable?
13. how to size low voltage cable?
14. how to size a battery cable?
15. how to size an electrical cable per the NEC?

 
One common theme for all “How to Size a Cable”
Questions:
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Home
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2.  To let you know that while each way the question if phrased by each different electrical professional it all comes
back to the one simple answer when determining sizing of cables here in the United States. How to properly size a
cable per the NEC. All roads lead to Rome and all those questions above (15) and below (100) lead to the same
place, here!

At what point in the electrical construction process does


“how to size a cable?” questions come up the most?
Just like you, these electrical professionals want to be sure they are measuring cables sizes the right way
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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
professionals pulling wire or installing cable to keep America running strong.

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.

The work you do is important and sizing a cable the right way is critical for the infrastructure of American.
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Photo Credit: New York Times (http://www.nytimes.com/interactive/2017/02/10/nyregion/how-new-york-city-gets-


its-electricity-power-grid.html), “How New York Gets it’s Electricity”

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
(http://www.ecmweb.com/), Electrical Contractor Magazine (http://www.ecmag.com/), and other great resources to
get you the answer to How to Size a Cable (https://1xtechnologies.com/wire-cable-products/):
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(http://youtu.be/k7d03Tic6LE)

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How to size a cable per the NEC without variables, the


simple answer from Paul Abernathy:

(https://1xtechnologies.com/how-to-size-a-cable/simple-
answer-on-how-to-size-a-cable-per-the-nec-without-
variables-1xtech/)

Simple Answer on How to Size a Cable per the NEC without


variables 1XTech
How to size a cable with 3 Current-Carrying Conductors or Less and no Ambient Temperature Corrections as told to
our Manufacturers Rep USA (https://usafactoryrep.com/) by Paul Abernathy
(https://1xtechnologies.com/)
(http://www.linkedin.com/in/paulabernathy/), code expert, and owner of Electrical Code Academy
(http://www.electricalcodeacademy.com/).
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Step 1- Determine the Load on the Cable using Article 220, Part II of the National Electrical Code
Reviews (https://1xtechnologies.com/customer-testimonials/)
(http://www.ecmag.com/section/systems/article-220-branch-circuit-feeder-and-service-calculations)
Electrical Wire & Cable Products (https://1xtechnologies.com/wire-cable-products/)
Step 2– Turn to Table 310.15(B)(16) (http://www.linkedin.com/pulse/understanding-31015b7-2014-nec-paul-w-
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abernathy-cmi/) of the National Electrical Code   (Scroll above or below to see Ampacity chart)
Quick Quote
Step (https://1xtechnologies.com/contact-1x-technologies-llc/)
3(A)– Load in Step 1 is 100A or less or conductors are sized 14 AWG through 1 AWG select conductor that
can handle the load from 60°C Column.
Step 3(B) – Load in Step 1 is over 100A or conductors are sized 1/0 AWG and Larger select conductor that can
handle the load from 75°C Column.

If you like the podcast we shared above and have 2


hours to listen to a master at work on cable sizing, here
is a fantastic video by Paul Abernathy:
(http://youtu.be/6w7lrfMxDiA)

 How to Size a Cable per the NEC with variables:


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the-nec-with-variables-1xtech/)

How to size a cable per the NEC with variables 1XTech

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).

Key Factors you must consider:

1. Continuous loads
2. Terminal temperature ratings
3. Conductor insulation
4. Conductor ampacity
5. Conductor bundling
6. Ambient temperature
7. Special application

NEC 240.4 Cable Sizing from Mike Holt


(http://www.linkedin.com/in/mikeholtnec/)
NEC 240.4  requires the branch circuit, feeder, and service conductors to be protected against overcurrent.

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:

Power Loss Hazard [240.4(A)]


Overcurrent Devices Rated 800A or Less [240.4(B)]
Small Conductors [240.4(D)]
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Tap Conductors [240.4(E)]
Transformer Secondary Conductors[240.4(F)]
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Air-Conditioning and Refrigeration Equipment Circuit Conductors [240.4(G)]
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Capacitor Circuit Conductors [240.4(G)]
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Electric Welder Circuit Conductors [240.4(G)]
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Fire Alarm System Circuit Conductors [240.4(G)]
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Motor-Operated Appliance Circuit Conductors [240.4(G)]
Motor and Motor-Control Circuit Conductors[240.4(G)]
Phase Converter Supply Conductors [240.4(G)]
Remote-Control, Signaling, and Power-Limited Circuit Conductors [240.4(G)]

Cable Size Selection Chart – NEC Ampacities Chart for


How to Size a Cable

(https://1xtechnologies.com/how-to-size-a-cable/nec-ampacity-table-v1-800pix/)
Cable Size Selection Chart
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The following steps and examples should help you
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understand
Electrical Wire & Cablethe basic
Products rules of how to size a cable per the
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NEC:
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1. Step 1 – Size the overcurrent device in accordance with 210.20(A) and 215.3. These two NEC rules require the
overcurrent device (breaker or fuse) be sized no less than 100% of the noncontinuous load, plus 125% of the
continuous load.
2. Step 2 – Select the conductor to comply with 210.19(A), 215.2, and 230.42(A). Sections 210.19(A), 215.2 and
230.42(A) require the conductor to be sized no less than 100% of the noncontinuous load, plus 125% of the
continuous load.   In addition, 110.14(C) requires consideration of the temperature rating of the equipment
terminals when sizing conductors. Circuit conductors must be sized according to the 60°C column of Table
310.15(B)(16) for equipment rated 100 amperes and less, unless marked otherwise, and equipment rated over 100
amperes must be sized to the 75°C column of Table 310.15(B)(16) [110.14(C)]. The purpose of this rule is to
ensure that the heat generated on equipment terminals can be properly dissipated without damaging the
conductors. For all practical purposes, most electrical equipment is designed to accept conductors sized to the
75°C column of Table 310.15(B)(16).
3. Step 3 – The selected conductor must be protected against overcurrent in accordance with 240.4. This requires
the branch circuit, feeder, and service conductors be protected against overcurrent in accordance with their
ampacities as specified in Table 310.15(B)(16).

(http://youtu.be/OLIHEiiY_Rs)

Branch Circuit Continuous Load Example for How to


Size a Cable
What size branch-circuit over-current protection device and conductor (THHN) is required for a 23A continuous load
(75°C terminals).
1. Step 1 – Size the overcurrent protection device in accordance with 210.20(A) – The branch-circuit overcurrent
device must be sized not less than 125% of 23A.   23A x 125% = 28.75A or 30A [240.6(A)]   
protection(https://1xtechnologies.com/)
2. Step 2 – Select the conductor to comply with 210.19(A), which requires the branch-circuit conductor to be sized
no less than 125% of the continuous load, 23A x 125% = 28.75A. The conductor is selected to the 75°C
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temperature rating of the equipment terminals in accordance with Table 310.15(B)(16). In this case, 10 THHN
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having a rating of 35A at 75°C is suitable.
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3. Step 3 – We must ensure the conductor is protected against overcurrent in accordance with the requirements of
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240.4. Again in this case, 10 THHN (from Step 2) rated 35A [Table 310.15(B)(16) is protected by the 30A
Quick Quote device.
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Feeder Continuous Load Example for How to Size a


Cable: 

(https://1xtechnologies.com/how-to-size-a-cable/single-conductor-wires-
1xtech/)

Feeder Continuous Load Example for How to Size a Cable,

Feeder Continuous Load Example for How to Size a Cable: 

What size feeder overcurrent protection (http://www.ecmweb.com/code-basics/nec-rules-overcurrent-protection-


equipment-and-conductors) device and conductor (THHN) is required for a 184A continuous load on a panelboard
(75°C terminals).

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).

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Preventing Fire and Overheating with NEC minimum


cable size requirements for cables to comply with OSHA
Safety (http://www.osha.gov/)
The NEC (http://www.nfpa.org/NEC/About-the-NEC/Free-online-access-to-the-NEC-and-other-electrical-standards)
provides minimum size requirements for conductors to prevent overheating and fire. Insulation type, ambient
temperature, and conductor bundling are three primary factors in determining how big a conductor has to be for it to
safely carry the current imposed on it.

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.

YouTube Video OSHA Electrical Safety Presentation (38


Mins 16 seconds)
This is an excellent electrical presentation by Rodney Sherman given at Holy Cross Energy. It will make a believer out
of you.

Video from the actual OHSA Acadamy course, you can check out the course here
(https://www.oshatrain.org/courses/mods/615m1.html).
 
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Temperature correction in cable sizing


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Table 310.16
Electrical lists&
Wire ampacities under two
Cable Products conditions: 1) no more than three current-carrying conductors bundled
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together,
Because and
You2)Require
an ambient temperature
Quality, of®
Quickly! 86°F (30°C). If either of these two values changes, the ampacity of the
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conductor must change as well. If you look at the bottom of Table 310.16, you’ll see temperature correction factors in
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5°C increments from 21°C through 80°C.

Sizing cables per Conductors and Temperature


When sizing conductors, you can’t use a temperature rating any higher than the lowest temperature rating of any
connected termination or device [110.14(C)]. Generally, you don’t find terminals rated above 75°C, so why is there a
90°C column for conductors? True, most terminations simply aren’t rated to carry 90°C, but remember that when you
adjust the ampacity of a conductor due to ambient temperature or conductor bundling, you use the 90°C column to
begin the calculation (assuming you are using a conductor 90°C insulation rating). Read through example D3(a) in
Annex D, and you’ll understand exactly why this column exists.

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.

Mike Holt (http://www.linkedin.com/in/mikeholtnec/):


Practice example for sizing a cable, how to size a cable.
What’s the minimum size THHN/THWN conductor you can use to supply a 40A noncontinuous load in a dry location,
if the conductors pass through an ambient temperature of 100°F (Fig. 1)?

Corrected Ampacity = Table 310.16 Ampacity × Ambient Temperature Correction Factor

For a dry location, use the 90°C column for THHN.

Ambient Temperature Correction Factor for 100°F = 0.91 for THHN

Table 310.16 ampacity for 10 THHN is 40A at 90°C in a dry 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.

8 THHN = 55A × 0.91 = 50A

Therefore, an 8 AWG conductor is the answer to this question.

If this were in a wet location, would 8 THHN/THWN still be adequate?


Table 310.16 ampacity for 8 THWN is 50A at 75°C in a wet location: use the THWN 75°C column.
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Ambient Temperature Correction Factor for 100°F = 0.88 for THWN

8Home
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= 50A × 0.88 = 44A About (https://1xtechnologies.com/about-1x/)
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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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dry location. That either/or result is not always the case, so pay attention to the wet/dry question when using
Quick Quote
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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.

Bundling: How to size bundled cable

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bundled-cable-wire-mobile/)

How to size Bundled Cable, How to size Bundled Wire, NEC


Bundled Wire, NEC Bundled Cable, Code for Bundled Wire, Code
for Bundled Cable

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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cable-800px-mobile/)

NEC Table 310.16 1XTECH How to size a cable

To make that cable sizing adjustment, multiply these three numbers together:

Table 310.16 ampacity


Temperature correction factor
Bundling adjustment factor.

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).

Cable sizing with Current-carrying conductors


Table 310.15(B)(2)(a) adjustment factors apply only when there are more than three current-carrying conductors
bundled together. All phase conductors are considered current-carrying, but what about other conductors?
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cable-1xtech-optimized-800px/)

NEC Table 310.15 B 2 a How to size a cable 1XTech, Cable sizing with Current-carrying
conductors

Here’s the rundown:

 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.

Meeting minimums of conductor size when choosing


your cable size
From an NEC standpoint, conductors must be of a certain size to prevent a fire [90.1(B)]. This is
the minimum conductor size, not necessarily the recommended conductor size. From an operational efficiency
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standpoint, you should size conductors to reduce voltage drop and/or to cope with nonlinear loads. Other reasons for
exceeding NEC minimums may also apply.
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your installation doesn’t even meet the NEC requirements, it will fail to meet other requirements that may also exist
Electrical
(such Wire
as those for& Cable Products
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efficiency). To prevent that, remember the ampacity of a conductor changes with
Because conditions.
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job in sizing conductors is to anticipate what those conditions will be. To determine
the correct
Quick ampacity,
Quote you have to determine:
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Allowable ampacity, as listed in Table 310.16.


Ambient temperature correction factors, if the ambient temperature is not 86°F.
Conductor ampacity adjustment factors, if four or more current-carrying conductors are bundled together.

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.

Resistance and Voltage Drop Calculator via YouTube


Video (14 Minutes 16 Seconds)
This is a very good video from Dunwoody College teaching resistance and voltage drop you may use for your Traction
Power Cable calculations.

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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Cable Sizing Disclaimer:


1X Technologies Cable Company has made every effort to ensure that the results of this article are correct and helpful
to you on your job. However, we advise you to reference your NEC handbook to double-check all your work. We
disclaim all liability from usage of this information in cable sizing.
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