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The National Electrical Code requirements for conductor sizing and overcurrent protection have always been confusing and complex. Factors that must be consider include:
1. 2. 3. 4. 5. 6. Continuous loads Terminal temperature ratings Conductor insulation Conductor ampacity Special application System voltage
NEC Section 240-3 requires the branch circuit, feeder, and service conductors to be protected against overcurrent in accordance with their ampacities as specified in Table 310-16. However, Section 240-3 contains twelve rules that modify the general requirement and permit the conductors not to be protected in accordance with their ampacities, they include: 1. Power Loss Hazard 2. Devices Rated 800 Amperes or Less 3. Tap Conductors 4. Motor-Operated Appliance Circuit Conductors 5. Motor and Motor-Control Circuit Conductors 6. Phase Converter Supply Conductors 7. Air-Conditioning and Refrigeration Equipment Circuit Conductors 8. Transformer Secondary Conductors 9. Capacitor Circuit Conductors 10. Electric Welder Circuit Conductors 11. Remote-Control, Signaling, and Power-Limited Circuit Conductors 12. Fire Alarm System Circuit Conductors With so many different Code rules that modify the general requirements, it does become overwhelming to a circuits conductor and overcurrent protection device. However the following steps and examples should help you understand the basic rules of conductor sizing and protection. Step 1 - Size the overcurrent protection device in accordance with Sections 21020(a), 215-3, and 384-16(d). These three NEC rules required the overcurrent protection device (breaker or fuse) be sized no less than 100% of the noncontinuous load, plus 125% of the continuous load. Section 240-6(a) contains the list of standard size overcurrent protection devices. Step 2 - Select the conductor to comply with Sections 110-14(c), 210-19(a), 215-2, and 230-42(a). Sections 210-19(a), 215-2 and 230-42(a) required the conductor to be sized no less than 100% of the noncontinuous load, plus 125% of the continuous load. In addition, Section 110-14(c) requires a consideration of the temperature rating of the equipment terminals when sizing conductors. Section 110-14(c) requires the circuit conductors to be sized according to the 60C column of Table 310-16 for equipment
rated 100 amperes and less, unless marked otherwise, and equipment rated over 100 amperes must be sized to the 75C column of Table 310-16. Authors Comment. These important Code rules were added to the 1993 and 1996 NEC and are often overlooked. The purpose of these new rules are to insure that the heat generated on the equipment terminals can be properly dissipated without damaging the conductors. For all practical purposes, most electrical equipment is design to accept conductors sized to the 75C column of Table 310-16. Step 3 - The selected conductor must be protected against overcurrent in accordance with Section 240-3. Section 240-3. This requires the branch circuit, feeder, and service conductors be protected against overcurrent in accordance with their ampacities as specified in Table 310-16. However, Section 240-3(b) permits "the next size up device" if the conductors are not part of a multioutlet branch circuit supplying receptacles, and the ampacity of the conductors does not correspond with the standard ampere rating of a overcurrent protection fuse or a circuit breaker as listed in Section 240-6(a), and the next higher standard rating selected does not exceed 800 amperes. Authors Comment. The ampacity of a conductor is its current rating in amperes that it can carry continuously, after applying conductor ampacity reduction factors for conductor bundling and ambient temperature. In addition, the 1996 clarified in Section 110-14(c), that the ampacity reduction of THHN (90C) conductor is based on the conductors ampacity as listed in the 90C column of Table 310-16 and not on the terminal temperature rating.
terminals. No. 6 THHN has a rating of 65 amperes at 75C and can not be used, therefore we must select a No. 4 which has a rating of 85 amperes at 75C. Step 3 - The No. 4 THHN conductor must be protected against overcurrent in accordance with Section 240-3. We must verify that the No. 4 THHN is properly protected against overcurrent by the 70 ampere overcurrent protection device. Since we have more than three current-carrying conductors in the same raceway, we must correct the No. 4 THHN conductors ampacity as listed in the 90C column of Table 310-16. Corrected Ampacity No. 4 THHN = Ampacity x Note 8(a) Adjustment Factor Corrected Ampacity No. 4 THHN = 95 amperes x 80% Corrected Ampacity No. 4 THHN = 76 amperes The No. 4 THHN which is rated 76 amperes after ampacity correction is properly protected by a 70 ampere overcurrent protection device in compliance with the general requirements of Section 240-3.