Conductor Sizing — Part 1 of 2

Do you understand the basic concepts behind conductor sizing?

Mike Holt | May 14, 2019

The National Electrical Code (NEC) requires a given conductor to be a

minimum size for a given load under specific conditions of use. The reason
for this is to protect the conductor insulation from overheating. So, to
understand conductor sizing, you need to understand a little about
conductor insulation.

Table 310.104(A) provides information on conductor insulation properties,

such as letter type, operation temperature, application, insulation, and
outer cover properties. Only conductors in Tables 310.104(A) though
310.104(E) can be installed, and a given conductor can be used for only the
application(s) the tables identify it for.

Related: The Basics of Conductor Sizing — Part 1

In general, you can use only conductors contained in Tables 310.104(A),

except where otherwise permitted in the NEC (an example being PV wire
[690.31(C)]).

It’s common to see conductors with a dual insulation rating, such as

THHN/THWN. You can use this type of conductor in a dry location at the
THHN 90°C ampacity. If you use it in a wet location, you must adhere to
the THWN ampacity rating of the 75°C column of Table 310.15(B)(16) for
THWN insulation types. When the insulation type has the suffix “-2”, you
can use the conductor in a wet or dry location at the 90°C ampacity rating.
THWN-2 is an example.

Conductor Sizes

Related: The Basics of Conductor Sizing — Part 2

Conductor sizes are expressed in American Wire Gage (AWG), typically

from 18 AWG up to 4/0 AWG. Conductor sizes larger than 4/0 AWG are
expressed in kcmil (thousand circular mils) [Sec. 110.6].

There’s a misconception that 12 AWG copper is the smallest conductor

permitted for commercial or industrial facilities. Although this isn’t true
based on NEC rules, it may be a local code requirement or otherwise
specified for the project.

The smallest conductor permitted for branch circuits for residential,

commercial, and industrial locations is 14 AWG copper, except as permitted
elsewhere in the NEC [Sec. 310.106].

You can use conductors smaller than 14 AWG for:

• Class 1 remote-control circuits [Sec. 725.43].

• Fixture wire [Sec. 402.6].

• Motor control circuits [Table 430.72(B)].

Conductors 8 AWG and larger must be stranded when installed in a
raceway unless specifically permitted elsewhere [Sec. 310.106(C)]. Solid
conductors are often used for the grounding electrode conductor [Sec.
250.62] and for bonding pools, spas, and outdoor hot tubs [Sec.
680.26(C)].

You must size conductors using their ampacity from the insulation
temperature rating column of Table 310.15(B)(16) that corresponds to the
lowest temperature rating of any terminal, device, or conductor of the
circuit.

For motors marked with design letters B, C, or D, you can use conductors
having an insulation rating of 75°C or higher if the ampacity of such
conductors doesn’t exceed the 75°C ampacity listed in Table 310.15(B)(16)
[110.14(C)(1)(a)(4)].

For equipment rated 100A or less, you must size the conductors using the
60°C temperature column of Table 310.15(B)(16) [110.14(C)(1)(a)(2)].

Where you have terminals for equipment rated over 100A and/or pressure
connector terminals for conductors larger than 1 AWG, you must size the
conductor per the 75°C temperature rating listed in Table 310.15(B)(16)
[110.14(C)(1)(b)(1)].
Fig. 1. It’s important to know the temperature rating of your pressure
connectors when sizing your conductors.

Conductors rated 90°C and that terminate on separately installed pressure

connectors can be sized to the 90°C column of Table 310.15(B)(16) if the
conductors and pressure connectors are rated at least 90°C [110.14(C)(2)]
(Fig. 1).

Overcurrent Protection

Conductor sizing and overcurrent protection sizing go hand in hand, so let’s

look briefly at overcurrent protection.
Article 240 covers the general requirements for overcurrent protection and
the installation requirements of overcurrent protection devices (OCPDs).
Overcurrent is a condition where the current exceeds the rating of
equipment or ampacity of a conductor due to overload, short circuit, or
ground fault [Art. 100].

An OCPD protects the circuit by opening when the current reaches a value
that will cause an excessive or dangerous temperature rise (overheating) in
the protected conductor(s). OCPDs must have an interrupting rating
sufficient for the maximum possible fault current available on the line-side
terminals of the equipment [Sec. 110.9]. Electrical equipment must have a
short-circuit current rating (SCCR) that permits the circuit’s OCPD to clear
short circuits or ground faults without extensive damage to the circuit’s
electrical components [Sec. 110.10 Note].

There are many different rules for protecting conductors and equipment.
It’s not simply using 12 AWG wire and a 20A breaker. The general rule is
that conductors must be protected at the point where they receive their
supply per their ampacities, as listed in Table 310.15(B)(16) [Sec. 240.21].
Except as permitted by Sec. 240.4(A) through (G), conductors must be
protected against overcurrent per their ampacity after ampacity correction
and adjustment required in Sec. 310.15.

For OCPDs rated 800A or less [Sec. 240.4(B)], the next higher standard
rating of OCPD listed in Sec. 240.6(A) (above the ampacity of the
ungrounded conductors being protected) is permitted. But only if all the
following conditions are met:
(1) The conductors aren’t part of a branch circuit supplying more than one
receptacle for cord- and plug-connected loads.

(2) The ampacity of a conductor, after the application of ambient

temperature correction [Sec. 310.15(B)(2)(a)], conductor bundling
adjustment [Sec. 310.15(B)(3)(a)], or both, doesn’t correspond with the
standard rating of a fuse or circuit breaker in Sec. 240.6(A).

(3) The next higher standard OCPD rating from Sec. 240.6(A) doesn’t
exceed 800A.

Let’s run through some example problems to drive these points home.

Example No. 1

What’s the maximum size OCPD that can be used to protect 1 AWG
conductors, where each conductor has an ampacity of 130A at 75°C, per
Table 310.15(B)(16), and the calculated load is 104A?

A quick check of the Table reveals the answer to be 150A [Sec. 240.6(A)].

Example No. 2

What’s the maximum size OCPD that can be used to protect 500kcmil
conductors, where each conductor has an ampacity of 380A at 75°C, per
Table 310.15(B)(16), and the calculated load is 370A?

A quick check of the Table reveals the answer to be 400A [Sec. 240.6(A)].
If the circuit’s OCPD exceeds 800A, the conductor ampacity must have a
rating of not less than the rating of the OCPD [Sec. 240.4(C)]. But that’s
only after the application of ambient temperature correction [Sec.
310.15(B)(2)(a)], conductor bundling adjustment [Sec. 310.15(B)(3)(a)], or
both.

See if you can answer this question.

What’s the minimum size 75°C conductors allowed to be protected by a

1,200A OCPD using three sets of conductors per phase (Fig. 2)?
Fig. 2. If the circuit’s overcurrent device exceeds 800A, the conductor
must have an ampacity not less than the overcurrent device rating.

You first need to determine the conductor ampacity per raceway:

1,200A ÷ 3 = 400A

A quick check of Table 310.15(B)(16) shows a 600kcmil conductor is rated

for 420A at 75°C.
Total conductor ampacity = 420A × 3 conductors = 1,260A

Small Conductors

Unless specifically permitted in Sec. 240.4(E) or (G), overcurrent

protection must not exceed the following [240.4(D)]:

(1) 18 AWG Copper, 7A

(2) 16 AWG Copper,10A

(3) 14 AWG Copper, 15A

(4) 12 AWG Aluminum/Copper-Clad Aluminum, 15A

(5) 12 AWG Copper, 20A

(6) 10 AWG Aluminum/Copper-Clad Aluminum, 25A

(7) 10 AWG Copper, 30A

What about transformer secondary conductors? The primary OCPD sized

per Sec. 450.3(B) is considered suitable to protect the secondary
conductors of a 2-wire (single-voltage) system — but only if the primary
OCPD doesn’t exceed the value determined by multiplying the secondary
conductor ampacity by the secondary-to-primary transformer voltage ratio
[Sec. 240.4(F)].

Overcurrent Protection for Specific Applications

Overcurrent protection for specific equipment and conductors must comply
with the requirements referenced in Table 240.3.

Air-conditioning and refrigeration equipment, and their circuit conductors,

must be protected against overcurrent per Sec. 440.22. Typically, the
branch-circuit ampacity and OCPD size are marked on the equipment
nameplate [Sec. 440.4(A)].

Let’s look at an example problem.

What size branch-circuit OCPD is required for an air conditioner when the
nameplate indicates the minimum circuit ampacity is 23A, with maximum
overcurrent protection of 35A?

Answer: 10 AWG, 35A protection (See nameplate). Equipment must be

installed per the manufactures instructions [Sec. 110.3(B)].

Motors and their circuit conductors must be protected against overcurrent

per Art. 430 [Sec. 240.3].

Let’s run through a motor example problem now.

What size branch-circuit conductor and OCPD (circuit breaker) is required

for a 1-hp, 115V, single-phase motor with 60°C terminals (Fig. 3)?
Fig. 3. Here’s a simple example of how to protect a motor branch circuit
from short circuits and ground faults.

Answer: 12 AWG rated 20A at 60°C branch-circuit conductor with a 40A

OCPD.
Now Art. 430 requirements apply [Table 240.3].

Sec. 460.6(A)(1), use motor full-load current (FLC) from appropriate tables
to size conductors and OCPD. Table 430.248 gives the motor FLC for a 1-
hp, 115V motor, 16 FLC.

Motor conductor size, use Sec. 430.22, 16 FLC × 125% = 20A, Table
310.15(B)(16), 12 AWG rated 20A at 60°C [110.14(C)(1)(a)(1)].

Motor OCPD size, use Sec. 430.52(C), circuit breaker uses 250% of FLC, 16
FLC × 250% = 40A which is a standard size [240.6(A)].

Getting it Right

Factors that affect conductor sizing include conductor ampacity, equipment

terminal temperature rating, continuous load factors, overcurrent current
protection requirements, conductor insulation temperature rating, ambient
temperature conductor ampacity correction, and conductor bundle
conductor ampacity adjustment.

You must account for all these to arrive at the minimum safe size for a given
conductor. You may want to exceed that size after considering factors such
as voltage drop, to optimize performance. However, you can never go below
that size.

If you’re sizing the conductors for a given system, you are probably also
sizing the overcurrent protection, so you need to understand both to do the
job right.
Conductor Sizing ― Part 2 of 2
To correctly determine the ampacity of a conductor, you must
understand and correct for its conditions of use.

Mike Holt | Jun 18, 2019

The ampacity of a conductor is the maximum current it can carry

continuously, under the conditions of use, without exceeding its
temperature rating [Article 100 Definition]. The key concept is “under the
conditions of use.” You must determine what those conditions are so you
can select the appropriate ampacity table and then apply the appropriate
correction factors.

The number of conductors bundled together is one of the conditions that

determines which ampacity table to use. For example, Table 310.15(B)(16)
lists conductor ampacities under the condition of no more than three
current-carrying conductors bundled together in an ambient temperature
of 86˚F.

Temperature Correction

Related: EC&M's 2020 Code Change Conferences

When installing conductors in an ambient temperature other than 78˚F to

86˚F, you must use the appropriate multiplier(s) listed in Table
310.15(B)(2)(a) to correct the Table 310.15(B)(16) ampacities [Sec.
310.15(B)(2)(a)].
When correcting conductor ampacity for elevated ambient temperature, the
correction factor used for 90˚C insulated conductors is based on the 90˚C
rating of the conductor. If the conductor is dual-rated, such as a
THWN/THHN rating, you must use the 75˚C rating of the conductor if in a
wet location.

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Related: Conductor Sizing — Part 1 of 2

That’s because the wet location will require the use of the THWN
characteristics, and THWN is a 75˚C rated conductor [Table 310.104(A)].

THWN-2 is an insulation type that’s acceptable in a wet location and is

rated for 90˚C in either a wet or dry location. When raceways are installed
in wet locations, the conductors inside them are considered to be in wet
locations and must be of a type allowed in wet locations [Secs. 300.5(B),
300.9, and 310.10(C)].

How do you determine the ambient temperature for the application of the
ampacity correction per Table 310.15(B)(2)(a) where raceways or cables are
exposed to direct sunlight and located less than 7/8 in. above the roof? Add
60˚F (33˚C) to the outdoor ambient temperature [Sec. 310.15(B)(3)(c)].
Exception: Type XHHW-2 insulated conductors aren’t subject to that
temperature adder.

Ampacity Adjustment

When conductors are bundled, their ability to dissipate heat is reduced. So,
the ampacity of a conductor must be reduced whenever four or more
current-carrying conductors are bundled together. Where four or more
current-carrying power conductors are within a raceway longer than 24 in.
[Sec. 310.15(B)(3)(a)(2)] — or where cables are bundled for longer than 24
in. — you must reduce the ampacity of each conductor per Table
310.15(B)(3)(a).

The “number of conductors” is the total number of conductors, including

spare conductors, adjusted per Sec. 310.15(B)(5) and (B)(6). It doesn’t
include conductors that can’t be energized at the same time.

The conductor ampacity adjustment of Table 310.15(B)(3)(a) doesn’t apply

to conductors in cable trays (Sec. 392.80 applies to those) [Sec.
310.15(B)(3)(a)(1)] or raceways not longer than 24 in. [Sec.
310.15(B)(3)(a)(2)] — nor does it apply to conductors within Type AC or
Type MC cable under the following conditions [Sec. 310.15(B)(3)(a)(4)]:

a. The cables don’t have an outer jacket,

b. Each cable has no more than three current-carrying conductors,

c. The conductors are 12 AWG copper, and

d. No more than 20 current-carrying conductors (ten 2-wire cables or six 3-

wire cables) are installed without maintaining spacing for a continuous
length longer than 24 in. Exception: A 60% adjustment factor applies if
the
number of current-carrying conductors in these cables exceeds 20, and
they are stacked or bundled for more than 24 in.

Where more than one ampacity applies for a given circuit length, you must
use the lowest ampacity value. When different ampacities apply, the higher
ampacity can be used for the entire circuit if the reduced ampacity length
doesn’t exceed 10 ft or 10% of the length of the higher ampacity, whichever
is less [Sec. 310.15 (A)(2), Exception].

The Table 310.15(B)(3)(a) adjustment factors apply only when there are
more than three current-carrying conductors bundled together. All phase
conductors are considered current-carrying.

The following factors help determine if the neutral conductor is considered

a current-carrying conductor for the conductor ampacity adjustment of Sec.
310.15(B)(3)(a) [Sec. 310.15(B)(5)]:

• Both the neutral and ungrounded conductors of a 2-wire circuit carry

current. So, both are considered current-carrying.

• The neutral conductor that only carries the unbalanced current of a 3-

wire, single-phase, 120/240V circuit, or 4-wire, 3-phase, 120/208V or
277/480V wye-connected circuit, isn’t considered a current-carrying
conductor (Fig. 1).
Fig. 1. Neutral conductors that carry only unbalanced current from other
conductors from the same circuit aren’t considered current-carrying
conductors.

• The neutral conductor of a 3-wire circuit from a 4-wire, 3-phase, wye-

connected system carries about the same current as the line-to-neutral load
currents of the other conductors. So, it’s considered a current-carrying
conductor. In this situation, one of the line-to-neutral currents isn’t present
and can be zeroed out of the neutral current formula.
• The neutral conductor of a 4-wire, 3-phase, 120/208V or 277/480V wye-
connected circuit is considered a current-carrying conductor if more than
50% of the neutral load consists of nonlinear loads.

Also:

• Grounding and bonding conductors aren’t counted when adjusting

conductor ampacity for the effects of conductor bundling [Sec.
310.15(B)(6)].

• Wireways are commonly used where access to the conductors within the
raceway is required to make terminations, splices, or taps to several devices
at a single location. When more than 30 current-carrying conductors are
installed in any cross-sectional area of the wireway, the conductor
ampacity, as listed in Table 310.15(B)(16), must be adjusted per Table
310.15(B)(3)(a) [Sec. 376.22(B)].

• The allowable ampacity as listed in Table 310.15(B)(16) must be corrected

if the ambient temperature isn’t 86˚F from Table 310.15(B)(2)(a). It also
must be adjusted if there are four or more current-carrying conductors
bundled together, per the factors in Table 310.15(B)(3)(a).

Branch-Circuit Conductor Sizing Example

Section 210.19(A)(1) states that branch-circuit conductors cannot be sized

less than the larger of Sec.210.19(A)(1)(a) or (b).

Question: All conductor terminals are rated 75˚C. What size branch-circuit
conductor (THHN) is required for a 45A continuous nonlinear load that
requires three ungrounded conductors and a neutral (four current-carrying
conductors), as shown in Fig. 2?

Fig. 2. Here’s a good example of how to properly size a branch-circuit

conductor.
Section 210.19(A)(1)(a): Since the load is 45A continuous, the conductor
must be sized to have an ampacity of at least 56A (45A × 125%). Per Table
310.15(B)(16), 75˚C column [Sec. 110.14(C)(1)(a)(3)], a 6 AWG conductor is
suitable because it has a rating of 65A at 75˚C before any conductor
ampacity adjustment and/or correction is applied.

Section 210.19(A)(1)(b): Because the neutral is considered a current-

carrying conductor per Sec. 310.15(B)(5)(c), there are four current-carrying
conductors. Thus, we must apply the Table 310.15(B)(3) adjustment factor
of 80%. Section 110.14(C)(1)(a)(2) permits the use of the THHN 90˚C
ampacity rating for correction or adjustment.

6 THHN is 75A at 90˚C [Table 310.15(B)(16)]

The adjustment factor for four current-carrying conductors is 80% [Table

310.15(B)(3)(a)].

Corrected Ampacity = 75A × 80% = 60A, which is adequate for the 45A
load.

The larger of Sec. 210.19(A)(1)(a) and (b) is 6 AWG THHN.

The minimum branch-circuit conductor size must have an allowable

ampacity at least the maximum load to be served after the application of
adjustment or correction factors.

Feeder Conductor Sizing Examples

Feeder conductors must be sized to the larger of Sec. 215.2(A)(1)(a) or Sec.

215.2(A)(1)(b).
(a) The minimum feeder conductor ampacity must be no less than 125% of
the continuous load, plus 100% of the noncontinuous load, based on the
terminal temperature rating ampacities as listed in Table 310.15(B)(16)
[110.14(C)(1)].

(b) The minimum feeder conductor ampacity must be no less than the
maximum load after any adjustment or corrections factors.

Question No. 1: What size feeder conductor (THHN) is required for a 200A
continuous load (Fig. 3)?
Fig. 3. Here’s a good example of how to properly size a feeder conductor
serving a continuous load.

Answer No. 1: Since the load is 200A continuous, the conductors must be
sized to have an ampacity of at least 250A (200A × 125%). According to
Table 310.15(B)(16), 75˚C column [Sec. 110.14(C)(1)(b)(1)], a 250kcmil
conductor is suitable. That’s because it has an ampere rating of 255A at
75˚C before any conductor ampacity adjustment and/or correction is
applied [Sec. 215.2(A)(1)(a)].

Since the question doesn’t specify any ampacity adjustments or corrections,

the 250kcmil calculated in Sec. 215.2(A)(1)(a) is the larger of (a) and (b).

Question No. 2: What size feeder conductor (THHN) is required for a 100A
continuous load and 100A of noncontinuous load

Answer No. 2: Since the load is 100A continuous and 100A noncontinuous,
the conductors must be sized to have an ampacity of at least 225A (100A ×
1.25 + 100A). According to Table 310.15(B)(16), 75˚C column
[110.14(C)(1)(b)(1)], a 4/0 THHN conductor is suitable. That’s because it
has an ampere rating of 230A at 75˚C before any conductor ampacity
adjustment and/or correction is applied.

Since the question doesn’t specify any ampacity adjustments or corrections,

the 4/0 AWG calculated in Sec. 215.2(A)(1)(a) is the larger of (a) and (b).

Right Size, First Time

It’s not just embarrassing when an acceptance inspection reveals

conductors that are already installed are smaller than the Code minimum.
It’s expensive in project cost and schedule ramifications. To get it right
before installation, walk through your sizing process to check that you:

• Used the correct ampacity table for your conductor type and the number
bundled together.

• Used the correct temperature column (the one for the lowest-rated
device).

• Corrected for ambient temperature.

If the project includes performance expectations, the Code minimums

might not be enough. But you must get those right so you have a sound
basis for any upsizing decisions that involve non-Code factors such as
voltage drop.