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Chapter Three: Design of installation systems

3.1 Terms and definitions


3.2 Load estimation
3.3 General design procedure
3.4 Branch circuit design guidelines
Residential
Non-residential: Schools, Office spaces, Industrial spaces
3.5 Load tabulation
3.6 Feeder capacity
3.7 Service equipment and switch board design
3.8 Cable size determination
Design procedure and diversity factor

3.1 Terms and definitions

Ampacity: also described as current rating or current-carrying capacity, is the RMS


electric current which a device can continuously carry while remaining within its
temperature rating.

Appliance: utilization equipment; a device that operates by electricity including lights


and heaters, not just machines with moving parts.

Branch circuit: the circuit conductor between the final over current device protecting
the circuit and the outlet(s).

Demand factor: the ratio of the maximum demand of a system, or part of a system, to
the total connected load of a system or the part of the system under consideration.

Feeder: all circuit conductors between the service equipment, or the generator switch
board of an isolated plant, and the final branch circuit over current device (protection
device).

Ground: a conductor connection, whether intentional or accidental, between an electric


circuit or equipment and the earth, or to some conducting body that serves in place of
the earth.

Lighting outlet: an outlet intended for direct connection of a lamp holder, a light fixture,
or a pendant cord terminating in a lamp holder.

Outlet: a point on the wiring system at which current is taken to supply utilization
equipment.

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Receptacle: a contact device installed at the outlet for the connection of a single
attachment plug.

Service equipment: The necessary equipment, usually consisting of a circuit breaker or


switch and fuses, and their accessories, located near the point of entrance of supply
conductors to a building or other structure, or an otherwise defined area, and intended
to constitute the main control and means of cutoff of the supply.

Switch board: a large panel, frame or assembly of panels on which are mounted, on the
face or back or both, switches, over current and other protective devices, buses, any
usual instruments.

Wiring Design Criteria

a) Flexibility: every wiring system should incorporate sufficient flexibility of design in


branch circuitry, feeders, and panels to accommodate all portable, patterns,
arrangements and locations of electric loads. The degree of flexibility to be incorporated
depends in large measure on the type of facility. As part of the design for flexibility,
provision for expansion must be provided. It must, however, be emphasized that over
design is as bad as under design.

b) Reliability: the reliability of electrical power within a facility is determined by two


factors: the utility’s service and the building’s electrical system.

c) Safety: the designer must be constantly alert to an initial safe electrical installation
and such factors as electrical hazards caused by misuse of equipment or by equipment
failure after installation.

d) Energy consideration: includes limiting voltage drops, power factor correction, use of
switches for control, etc.

e) Economic cost: includes initial cost and operating cost.

f) Space allocation: concerned with maintenance ease, ventilation, expandability,


centrality, limitation of access, and noise, in addition to the basic item of space
adequacy.

3.2 Load Estimation

When initiating the wiring design of a building, it is important to be able to estimate the
total building load in order to plan such spaces as transformer rooms and closet. This
information is also required by the local power company well in advance of the start of
construction. Of course, an exact load total can be made after completing the design.

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Such estimation can be made from the knowledge of the loads the building uses. The
electrical loads in any facility can be categorized as:

a) Lighting
b) Miscellaneous power, which includes convenience outlets and small motors
c) Heating, ventilating, and air conditioning
d) Plumbing or sanitary equipment: house water pump, air compressors, and
vacuum pumps etc.
e) Vertical transportation equipment: elevators, moving stairs, and dumbwaiters
f) Kitchen equipments
g) Special equipment

Design procedure

The steps involved in the electrical wiring design of any facility are outlined below.
These may, in some instances, be performed in different order, or two or more steps
may be combined, but the procedure normally used is that listed below.

(a) Make an electrical load estimate based on areas involved, building data, and any
other pertinent data.

(b) In cooperation with the local electric utility, decide upon the point of service
entrance, type of service run, service voltage, metering location, and building utilization
voltage.

(c) Determine with the client the usage of all areas, and type and rating of all client
furnished equipment including their specific electric ratings and service connection
requirements.

(d) Determine from other consultants such as HVAC, plumbing, elevators, kitchen, etc.,
the exact electrical rating of all the equipment in their designs.

(e) Determine the location and estimate the size of all required electric equipment
spaces including switchboard rooms, emergency equipment spaces, electric closets, and
so forth. Panel boards are normally located in closets but may be located in corridor
walls or elsewhere. This work is necessary at this point to enable the architect to reserve
these spaces for the electrical equipment. Once the design is accomplished in detail, the
estimated space requirements can be checked and necessary adjustments made.

(f) Design the lighting for the facility. This step is complex and involves a continued
interaction between the architect and the lighting designer.

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(g) Depending on the type of facility, it may be necessary to separate the lighting layout
from the receptacle and signal device layout for the sake of clarity of the plans. Once the
decision has been made as to how this is to be handled, the lighting fixture layout can
be made.

(h) On the same plan, or on a separate plan, as decided, locate all electrical apparatus
including receptacles, switches, motors, and other power consuming apparatus. Under
floor duct and ceiling track systems would be shown at this stage. If extensive, a
separate plan is made.

(i) On the plans, locate signal apparatus such as phone outlets, speakers, microphones,
TV outlets, fire and smoke detectors, and so on. Since many of these systems are
covered by special drawings or by specification alone, this step may be limited to
showing phone outlets only.

(j) Circuit all lighting, devices, and power equipment to the appropriate panels, and
prepare the panel schedules. Included in this step is the separate circuitry for
emergency equipment.

(k) Compute panel loads.

(1) Prepare the riser diagram. This includes design of distribution panels, switchboards,
and service equipment.

(m) Compute feeder sizes and all protective equipment ratings.

(n) Check the preceding work.

(o) Coordinate the electrical work with the other trades and with the architectural plans.
This is not really a separate step, but a continuing process starting at (i) above and
covering all subsequent stages of the work.

3.4 Branch Circuit Design Guidelines

I) Residential

National Electric Code (NEC): A safety code regarding the use of electricity. The NEC is
sponsored by the National Fire Protection Institute. It is also used by insurance
inspectors and by many government bodies regulating building codes.

(a) The NEC requires for residences sufficient circuitry to supply a load of 3w/sq ft in the
building, excluding unfinished spaces such as porches, garages, and basements.

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(b) The NEC requires a minimum of two 20-amp appliance branch circuits to feed all the
small appliance outlets in the kitchen, pantry, dining room, and family room, and only
these outlets. Furthermore, all kitchen outlets must be fed from at least two of these
circuits (which may also feed other appliance outlets). This NEC requirement needs
clarification. The NEC requires that at least two circuits be reserved for appliance
outlets, but it does not specify what these appliance outlets are except to say, by
inference, that all kitchen outlets are appliance outlets. In effect, then, according to the
NEC all the receptacles are potential appliance outlets and at least two circuits should
be supplied to serve them. Good practice dictates that certain receptacles in each room
be designated as appliance outlets even though they do not differ from the other
outlets in appearance. These outlets are:

1. All kitchen receptacles.


2. One dining room receptacle.
3. One receptacle in the family (or living) room.

These receptacles should be circuited with preferably two, but no more than four, such
outlets on a 20-amp circuit, and the circuits should be arranged so that the kitchen has
part of at least two circuits feeding its outlets.

(c) Additional circuits similar to appliance circuits should be furnished to supply one
outlet in each bedroom of a house that is not centrally air-conditioned. Such outlets are
intended for window air conditioners. (Good architectural and HVAC design will provide
window arrangement, attic ventilation, insulation, sun screening, and the like to obviate
the necessity for these noisy energy users.) Also, on circuits of this kind place basement
workbench outlets. These additional circuits must not be mixed with the appliance
branch circuits discussed above, as they are not strictly appliance circuits by NEC
definition.

(d) The NEC requires that at least one 20-amp circuit supply the laundry outlets. This
requirement satisfies good practice. If an electric clothes dryer is anticipated (and it
should be unless it is definitely known that a gas dryer will be used), an individual
branch circuit should be supplied to serve this load, via a heavy-duty receptacle.
(Obviously, facilities for hanging clothes must be provided for those who prefer not to
waste energy.)

(e) Lay out convenience receptacles so that no point on a wall is more than 6 ft from an
outlet. Use 20 amp, grounding-type receptacles only. Do not combine receptacles and
switches into a single outlet except where convenience of use dictates high mounting of
receptacles, as above counter spaces.

(f) Circuit the lighting and receptacles so that each room has parts of at least two
circuits. This includes basements and garages.

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(g) Avoid placing all the lighting in a building on a single circuit.

(h) Supply at least one receptacle in the bathroom and one outside the house. Both
must be GFCI types. This is an NEC requirement. An additional convenience is switch
control of the outside receptacle from inside the house. Also a timer-controlled outlet
for a plug-in bathroom heater is a welcome convenience, but obviously means
additional expense.

(i) In rooms without overhead lights, provide switch control for one-half of a
strategically located receptacle that is intended to supply a lamp. See Figure below for
the wiring arrangement in such a case.

(j) Provide switch control for closet lights. Pull chains are a nuisance (but are
considerably cheaper).

(k) In bedrooms supply two duplex outlets at each side of the bed location to
accommodate electric blanket, clocks, radios, lamps, and other such appliances.

(1) Since receptacles are counted as part of general lighting and no additional load is
included for them, no limit is placed on the number of receptacle outlets that may be
wired to a circuit. For good practice they should be limited to 6 on a 15-amp circuit and
8 on a 20-amp circuit.

(m) Kitchens should have a duplex appliance outlet every 36 in. of counter space, but no
less than two in addition to the normal wall outlets.

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(n) A disconnecting means, readily accessible, must be provided for electric ranges, cook
tops, and ovens. Plugs accessible by removal of a drawer or by reaching across a unit
meet the Code requirements but are not really “readily” accessible. It is better practice
to utilize a small kitchen panel recessed into a corner wall to control the large kitchen
appliances and to provide completely safe, accessible disconnecting means. Such an
arrangement can also be cheaper if the length of run between the main panel and the
kitchen is appreciable.

(o) Perimeter lighting, inside switch controlled, can do much to lessen vandalism and
discourage prowlers, in addition to illuminating the house at night. A complete
residential wiring plan for a small house is shown below.

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II) Non-residential

(a) Schools: Since schools comprise an assembly of varied use spaces, including
instruction, lab, shop, assembly, office, gymnasium, plus special areas such as swimming
pools, photographic labs, and so on, it is not possible to generalize on branch circuit
design considerations except for the following:
(1) To accommodate the opaque and film projectors frequently used in the
classroom, 20amp outlets wired two to a circuit are placed at the front and back
of each such room. A similar receptacle, wired 6 or 8 to a circuit is placed on
each remaining wall.

(2) Light switching should provide:


a. High-low levels for energy conservation and to permit low-level lighting
for film viewing. With fluorescent lighting this can be accomplished by
alternate ballast wiring and switching, thus avoiding the high cost of
dimming equipment.
b. Separate switching of the lights on the window side of the room, which
is often lighted sufficiently by daylight.

(3) Provide appropriate outlets for all special equipment in labs, shops, cooking
rooms, and the like.

(4) Use heavy-duty devices and key operated switches for public area lighting
(corridors, etc.), plastic instead of glass in fixtures, and vandal-proof equipment
wherever possible. All panels must be locked and should be in locked closets.

(5) The NEC requires sufficient branch circuitry to provide a minimum of 3 w/sq
ft for general lighting in schools. Refer to the NEC Article No. 220. Unlike
residential occupancy this figure does not include receptacles. Receptacles are
calculated separately at 180 w each for ordinary convenience outlets.

(6) Keep lighting and receptacles completely separate when circuiting.

(b) Office Space

(1) In small office spaces (less than 400 sq ft) provide either one outlet for every 40 sq ft,
or one outlet for every 10 linear ft of wall space, whichever is greater. In larger office
spaces, provide one outlet every 100 to 125 sq ft beyond the initial 400 sq ft (10
outlets). These should comprise wall outlets spaced as above plus floor outlets sufficient
to make up the required total. In view of the increasingly heavy loads of office
machines, these receptacles should be circuited at no more than 6 to a 20-amp branch
circuit, and less if the equipment to be fed so dictates.

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(2) Corridors should have a 20-amp, 220-v outlet every 50 ft, to supply cleaning and
waxing machines.
(3) As with all non-residential buildings, convenience receptacles are figured at 180 w
each.

(c) Industrial Spaces: These areas are so specialized that no meaningful guidelines can
be given.

(d) Stores. In stores, good practice requires at least one convenience outlet receptacle
for every 300 sq ft in addition to outlets required for loads such as lamps, show
windows, and demonstration appliances.

3.5 Load Tabulation

While circuiting the loads, a panel schedule is drawn up which lists the circuit numbers,
load description and wattage (actually volt-amperes), and the current rating and
number of poles of the circuit-protective device feeding each circuit. Spare circuits are
included to the extent that the designer considers them necessary and consonant with
economy, but normally no less than 20% of the number of active circuits. Finally, spaces
are left for future circuit breakers, in approximately the same quantity as the number of
spare circuits, but always to round off the total number of circuits. A typical panel
schedule is shown on the next page as an example.

In calculating panel loads, the following rules apply:

(a) Each specific appliance, device, lighting fixture, or other load is taken at its
nameplate rating, except certain kitchen and laundry appliances for which the NEC
allows a demand factor. (See NEC Article 220.)

(b) Each convenience outlet, in other than residential spaces, is counted as1.5 amp (180
W).

(c) Loads for special areas and devices such as show window lighting, heavy-duty lamp
holders, and multi outlet assemblies are taken at the figures given in NEC Article 220.

(d) Spare circuits are figured at approximately the same load as the average active
circuits.

Note: 1) In calculating total panel load, no demand factors may be applied except
specifically stated in the NEC. This is because feeders are calculated for
maximum load to be carried, i.e. 100% demand factor is used.
2) The phase loads have to be approximately equally distributed over the three
phases (if a three-phase supply is utilized in an installation). It is the
responsibility of the designer (or contractor) to circuit the loads so that the

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phases are as closely balanced in load as possible. If this is not done, one phase
will carry considerably more current than the others. Since the panel feeder
must be sized for the maximum phase current, this may lead to an over sized
feeder and therefore a waste of money.

Having tabulated and balanced the loads and totalled them by phase, the maximum
current is calculated. A portion of the spare capacity available in branch circuit is added
to the above total, as the basis for the calculation of the feeder load.

(e) Spaces are not added into the load.

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3.6 Feeder Capacity

To achieve economy, the panel feeder must accommodate the initial load plus some
portion of the future load. Spare capacity in feeders is provided by one or more of the
following procedures:

(a) Provide feeder (and conduit) capacity initially, to handle the entire eventual load.
This method is most expensive-requiring initial outlay for no return-and is rarely used.

(b) Provide feeder for initial plus spare with properly sized conduit. This method is
generally most economical.

(c) Provide feeder for initial plus spare, with conduit oversized by one size. Some
additional cost is entailed here. This is only used where large load expansion is
anticipated.

(d) Provide for initial load plus spare, with an empty conduit for future. This method is
expensive because of high conduit cost, and it is infrequently advisable.

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Riser Diagrams

When all devices are circuited and panels are located and scheduled, we are ready to
prepare a riser diagram. A typical diagram, shown in Figure below, represents a block
version of a single-line diagram except that, as the name implies, vertical relationships
are shown. All panels, feeders, switches, switchboards, and major components are
shown up to, but not including, branch circuiting.

3.7 Service Equipment and Switchboard Design

The main switchboard shown in the above figure constitutes a combination of service
equipment and feeder switchboard. The service equipment portion of the board

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comprises the metering and the 4 main switches feeding risers, motor control centre
(MCC), roof machine room, and elevators. The feeder board comprises switches 5
through 12. Such an arrangement is permissible inasmuch as the NEC allows up to 6
fused switches or circuit breakers to serve as the service disconnect means. This
arrangement was chosen in order to separate to the largest extent possible the motor
loads (elevators, air-conditioning equipment, basement power, etc.) from the lighting.
Such a procedure minimizes lighting fluctuations resulting from motor starting and
yields simpler maintenance. Also, the size of the main switch is reduced. This
switchboard would be of the metal clad dead-front type with switches or circuit
breakers, as desired. For protection of Feeder F10 designed above, an 800-amp circuit
breaker or 600A switch, with 400-amp trip or fuse, respectively, would be chosen,
assuming the initial installation to be a set of No. 500 MCM cables.

Other considerations and general rules affecting service equipment are listed below.

(a) A building may be supplied at one point by either a single set or parallel sets of
service conductors.

(b) Service drops may generally be not less than No. 8 AWG and service entrance
conductors or underground service conductors not less than No. 6 AWG.

(c) All equipment used for service including cable, switches, meters, and so on, shall be
approved for that purpose.

(d) It is recommended that a minimum of 100-amp, 3-wire, 220/380 v service be


provided for all individual residences.

(e) No service switch smaller than 60 amp or circuit breaker frame smaller than 50 amp
shall be used.

(f) In multiple occupancy buildings tenants must have access to their own disconnect
means.

(g) All building equipment shall be connected on the load side of the service equipment
except that service fuses, metering, fire alarm, and signal equipment and equipment
serving emergency systems may be connected ahead of the main disconnect.

In computing a size for the service equipment bus a total is taken of the various feeder
loads. Although application of a Diversity Factor to this total is permissible, good
practice dictates the use of a unity Diversity Factor in order to provide a measure of
spare capacity in the service equipment.

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