NEC 250 PART VIII: DIRECT CURRENT SYSTEMS

11. NEC 250 PART VIII: DIRECT CURRENT SYSTEMS

The grounding and bonding of direct current (DC) systems are primarily handled
by the Code the same manner as for alternating current (AC) systems, with only a
few differences. This makes sense, because DC systems are simply AC systems
that are at 0 Hz instead of the typical 50 or 60 Hz.

Many people think that DC systems cannot hurt you. This is not true. A rule of
thumb is that if a person is exposed to electrical energy for 1 s, 70 mA of 60-Hz
power is lethal, whereas 300 mA of DC power is lethal. There are many industrial
processes that utilize low-voltage (less than 60 V) DC electrical sources with very
high amperages (over 10,000 A) that can easily kill, such as electroplating,
chemical electrolysis systems, and electrolytic smelting. Unfortunately, many of
these types of systems are exempt from the National Electrical Code (NEC)
due to human safety studies that were conducted just after World War II. It is
important to understand that there is absolutely no basis for assuming that DC
electrical energy under 60 V is safe.

The principles for providing a safe electrical environment for people

working/living near AC systems is the same as for DC systems, regardless of the
voltage.

Grounding the neutral conductor to earth is just as important in DC systems as it

is in AC systems. Ensuring that you do not have erroneous neutral-to-ground
bonds in a DC system must be conducted as vigilantly as with AC systems. The
proper bonding and grounding of exposed non-current-carrying metal parts will
keep people safe in both AC and DC systems equally. And, of course, circuit
breakers and other overcurrent protection devices (OCPDs) will function reliably
when equipment-grounding conductors are properly installed for both AC and DC
systems.
In short, you should ground and bond DC systems in the same general manner as
AC systems.

11.1. 250.160. GENERAL

This section of the Code simply states that DC systems must comply with Part VIII
of Art. 250 and any other part of Art. 250 that is intended for DC systems. See
Arts. 250.6 (E) and 250.142(B), Exception No. 3 for more information.

11.2. 250.162. DIRECT CURRENT CIRCUITS AND SYSTEMS TO BE

GROUNDED

All DC systems must be grounded as stated in Art. 250.162(A) and (B), which
states that all three-wire DC systems must be grounded, and all two-wire DC
systems operating between 60- to 300-V DC must be grounded. See Art. 250.162
(A) and (B) for more information.

250.162(A). Two-wire, Direct Current Systems.   All two-wire DC systems

operating between 60- to 300-V DC must be grounded.

Given the recent understanding of DC arc flash, you should expect to see a
change in the rules regarding DC systems over 300 V in the future. Properly
grounding the exposed non-current-carrying metal components of these systems
will only help to protect personnel and equipment. See more information in the
last paragraph of this section.

If your DC system is less than 60-V DC, you do not have to ground it. However,
there is no provision saying that you cannot ground the system, and you probably
should. The exposed metal parts and metal chassis of systems using DC at less
than 60 V will only benefit from having a properly sized and routed equipment-
grounding conductor.

Equipment-grounding (bonding) conductor  The low-impedance

fault-current path that is typically run with or encloses the circuit
conductors, used to connect the non-current-carrying metal parts of
equipment, raceways, and other enclosures to the grounded (neutral)
conductor and equipment-grounding (bonding) conductor at service
equipment or at the source of a separately derived system. Often
called the green-wire or third-wire ground conductor.
If your DC system is over 300 V, the Code says that you do not have to ground
the system. Again, there is no provision saying that you cannot ground the
system, and you probably should. The exposed metal parts and metal chassis of
systems using DC at over 300 V will only benefit from having a properly sized and
routed equipment-grounding conductor. This is especially true given the hazards
that DC arc flash represents for personnel. Arc flash for DC systems can actually
be worse than for AC systems. The 2012 edition of the National Fire Protection
Association's Standard for Electrical Safety in the Workplace (NFPA 70E®) is just
beginning to discuss these issues, as there are no clear methods of accurately
calculating DC arc flash. But what is clear is that DC arc flash is a serious issue,
and properly grounded non-current-carrying components will be necessary.

Additionally, many DC systems are located near AC systems and are subject to
induced currents, harmonics, electrical noise, stray voltages, and other
objectionable currents inherent in AC systems. Ungrounded DC systems will have
no effective means of removing these stray voltages other than through the
neutral conductor of the electrical system, especially in isolated DC systems.
Proper grounding and bonding will only improve your electrical system.

Grounding of a DC system is in general to be conducted in the same manner as

grounding an AC system.

Exception no. 1: If your DC system is installed adjacent to or is integral

to the power supply, has ground detectors, and is only used to supply
industrial equipment in limited areas, it is not required to be grounded.

Exception no. 2: If you have an AC system that is in compliance with

Art. 250.20, that is, feeding power to a rectifier-derived DC system, you
are not required to ground the DC system.

The 2014 edition of the Code increased the DC voltage from 50 V to 60 V, and
required in Exception no. 1 that the source of power be adjacent to or integral to
the system.

250.162(B). Three-wire, Direct Current Systems.   All three-wire DC

systems shall be grounded regardless of the voltage.

Three-wire DC systems are not much different than any standard 208-V, single-
phase AC system, with the exception of the frequency (0 Hz). The neutral
terminal on the rectifier on a DC system will be grounded just as a neutral wire
would in an AC system.
Grounding of a DC system is in general to be conducted in the same manner as
grounding of an AC system.

11.3. 250.164. POINT OF CONNECTION FOR DIRECT CURRENT

SYSTEMS

Although the Code does not make it clear, this section is discussing both two-wire
and three-wire DC systems, which must be grounded in accordance with Art.
250.162(A) and (B).

Three-wire DC systems are not much different than any standard 208-V, single-
phase AC system, with the exception of the frequency (0 Hz). The center point of
the winding on an AC transformer (the XO) is 0 V, so we ground it at this point.
The same is true for a DC system, where the center point is 0 V, and we will
therefore ground it at this point. The wire attached to the zero point is the neutral
conductor (grounded conductor), just as in an AC system.

As with AC systems, you are to have one and only one neutral-to-ground
connection at the first service disconnect for the system. See NEC Art. 250 Parts
II and III for more information.

Two-wire DC systems are not much different than any standard 120-V, single-
phase AC system, with the exception of the frequency (0 Hz). The return
conductor of the two-wire DC system is the neutral, and it must be bonded to
ground in the first service disconnect, just as in an AC system.

First service disconnect  The very first electrical panel that will

disconnect (turn off) the power coming in from the utility company.
Sometimes this term is used to describe the first electrical panel that
can turn off power on the secondary or low-voltage side of a
transformer.

Neutral-to-ground connection (bond)  is where a grounded

current-carrying conductor, the neutral, is intentionally bonded to
earth/ground. In general, this should only occur at the transformer and
at the first service disconnect(s). The Code uses several names for
neutral-to-ground connections: system bonding jumper, main bonding
jumper, and supply-side bonding jumper.

And just as in an AC system, the grounding system for a DC circuits involves

connecting the non-current-carrying metal components to ground. All metal
chassis, enclosures, raceways, and so on are to be bonded to ground, just as in an
AC system. See NEC Art. 250 Parts IV, V, and VI for more information.

Direct current systems must also have grounding electrodes installed into the
earth/soil and grounding electrode conductors, just as in AC systems. These
electrodes and conductors must comply with NEC Art. 250 parts II, III, and V.

250.164(A). Off-Premises Source.  This section tells us that any DC supply

station(s) that is located off-premises from the building/structure it is providing
power for must have a ground connection made at one or more supply station(s).
A ground connection shall not be made at any individual services or premises.

Supply station, DC   A battery or a series of batteries, generator,

power supply, solar panel(s), or other device that provides DC electrical
power to a circuit.

First service disconnect  The very first electrical panel that will

disconnect (turn off) the power coming in from the utility company.
Sometimes this term is used to describe the first electrical panel that
can turn off power on the secondary or low-voltage side of a
transformer.

250.164(B). On-premises Source.  This section tells us that any DC supply

station(s) that is located inside or on the building/structure it is providing power
for must have a neutral conductor (grounded conductor) connected at one of the
following:

1. The source (at the supply station)

2. The first service disconnect or OCPD

3. Other listed system-protection equipment

 Supply station, DC   A battery or a series of batteries, generator,
power supply, solar panel(s), or other device that provides DC electrical
power to a circuit.

First service disconnect  The very first electrical panel that will

disconnect (turn off) the power coming in from the utility company.
Sometimes this term is used to describe the first electrical panel that
can turn off power on the secondary or low-voltage side of a
transformer.

Overcurrent device  Usually a fuse or circuit breaker, a device that

limits the maximum amount of current that can flow in a circuit.
Sometimes called an overcurrent protection device or OCPD.

Listed or listed item  An item, product, or device that has been

specifically developed for a particular function and has been
independently evaluated by a product-testing organization, such as the
UL or CE.

11.4. 250.166. SIZE OF DIRECT CURRENT GROUNDING

ELECTRODE CONDUCTOR

This section of the Code tells us that you must size the grounding electrode
conductor for DC systems in accordance with Art. 250.166(A) and (B), except as
allowed in Art. 250.166(C) through (E). Additionally, the grounding electrode
conductor is not required to be larger than a 3/0 copper or 250 kcmil aluminum.

Grounding (earthing) electrode conductor   The conductor used

to connect the grounding (earthing) electrode(s) to the equipment-
grounding (bonding) conductor, to the neutral (grounded) conductor, or
to both in accordance with Arts. 250.66 and 250.142.

In general, Table 250.66 (see Appendix B) can be used for proper sizing of
grounding electrode conductors for DC systems.

The 2014 edition of the Code placed a maximum size of 3/0 copper or 250 kcmil
aluminum for the grounding electrode conductor on DC systems.
250.166(A). Not Smaller Than the Neutral Conductor.   Two-wire DC
generators used in conjunction with balancer sets in order to obtain a neutral
point for three-wire systems must be equipped with OCPDs that electrically
disconnects the three-wire system, in accordance with NEC  Art. 445.12(D).
When this is the case, the grounding electrode conductor must be the same size
as the neutral conductor or an 8 AMG copper (or 6 AWG aluminum) conductor,
whichever is larger.

Overcurrent device  Usually a fuse or circuit breaker, a device that

limits the maximum amount of current that can flow in a circuit.
Sometimes called an overcurrent protection device or OCPD.

If this sounds like it refers to a very small set of DC systems, you are correct. This
rule only applies to DC systems with three-wire balancer sets or balancer
windings and with OCPDs. Please see Art. 250.166(B) for all grounding electrode
conductor requirements for all other DC systems.

250.166(B). Not Smaller Than the Largest Conductor.   This section deals
with grounding electrode conductor requirements of all DC systems other than
those in Art. 250.166(A). The grounding electrode conductor for DC systems must
be equal in size to that of the largest phase conductor or an 8 AWG copper (or 6
AWG aluminum) conductor, whichever is larger.

250.166(C). Connected to Rod, Pipe, or Plate Electrodes.   The grounding

electrode conductor does not need to be larger than a 6 AWG copper (or 4 AWG
aluminum) when it is the sole connection to a rod, pipe, or plate electrode, as in
Art. 250.52(A)(5) or (A)(7). This matches the requirements of AC systems that are
connected to ground rods, as found in Art. 250.66(A).

250.166(D). Connected to a Concrete-encased Electrode.   The

grounding electrode conductor does not need to be larger than a 4 AWG copper
when it is the sole connection to steel rebar in your concrete foundation
(concrete-encased electrode), as in Art. 250.52(A)(3). This matches the
requirements of AC systems that are connected to steel rebar in concrete
foundations (concrete-encased electrodes), as found in Art. 250.66(B).

Remember that aluminum is not allowed to come within 18 in. of the earth or to
be encased in concrete or to be used as an electrode, under Arts. 250.52(B)(1)
and 250.64(A).
250.166(E). Connected to a Ground Ring.   The grounding electrode
conductor does not need to be larger than the size of the copper ground ring
conductor when it is the sole connection to the ground ring, as in Art. 250.52(A)
(4). This matches the requirements of AC systems that are connected to ground
rings, as found in Art. 250.66(C).

What this section tells you is that for DC systems, you must reference Table
250.66 (see Appendix B) and size the grounding electrode conductor accordingly
or match the size of the ground ring. The minimum size for a ground ring is 2
AWG copper per Art. 250.52(A)(4).

Remember that aluminum is not allowed to come within 18 in. of the earth or to
be encased in concrete or to be used as an electrode, under Arts. 250.52(B)(1)
and 250.64(A).

11.5. 250.167. DIRECT CURRENT GROUND-FAULT DETECTION

This new section of the Code requires ground-fault monitoring and detection on
ungrounded DC systems and makes it optional to install them on grounded DC
systems. Proper marking is also required.

Ground fault  An unintentional connection between an energized

conductor and earth or metallic parts of enclosures, raceways, or
equipment.

This section is new to the 2014 Code.

250.167(A). Ungrounded Systems.  You are required to install ground-fault

detection systems on all ungrounded DC systems.

This section is new to the 2014 Code.

250.167(B). Grounded Systems.  You are permitted to install ground-fault

detection systems on grounded DC systems.

This section is new to the 2014 Code.

250.167(C). Marking.  You must identify the type of DC system that is in use

at the first service disconnect or at the supply by legibly and durably (must be
able to withstand the environment) marking it as "Grounded DC System" or
"Ungrounded DC System."
This section of code applies to all DC systems.

First service disconnect  The very first electrical panel that will

disconnect (turn off) the power coming in from the utility company.
Sometimes this term is used to describe the first electrical panel that
can turn off power on the secondary or low-voltage side of a
transformer.

Grounded (earthed)  Connected to earth/soil.

Ungrounded system  An electrical service that does not have any

of the current-carrying conductors intentionally grounded (i.e., no
neutral wire). Delta-type electrical systems and some standby
generators are examples of ungrounded systems.

This section is new to the 2014 Code.

11.6. 250.168. DIRECT CURRENT SYSTEM BONDING JUMPER

This section tells us that the grounding electrode conductor must be connected
to the neutral conductor (grounded conductor) at the first service disconnect. The
system bonding jumper must be the same size as the grounding electrode
conductor, as in Art. 250.166 above. You must also comply with all the main
bonding jumper and system bonding jumper rules found in Art. 250.28(A), (B),
and (C). Please see Art. 250.28 for more information.
 System bonding jumper   A conductor, screw, or strap that bonds
the equipment-grounding conductor to the neutral (grounded)
conductor; sometimes called the main bonding jumper. The term
system bonding jumper is used to distinguish the bond at the load side
of the service (at the first service disconnect) from the supply-side
bonding jumper, which is the bonding used on the utility or supply side
of the service. For more details, see Arts. 250.24(A)(4), 250.24(B),
250.28, and 408.3(C).

Neutral-to-ground connection (bond)  is where a grounded

current-carrying conductor, the neutral, is intentionally bonded to
earth/ground. In general, this should only occur at the transformer and
at the first service disconnect(s). The Code uses several names for
neutral-to-ground connections: system bonding jumper, main bonding
jumper, and supply-side bonding jumper.

Grounding (earthing) electrode conductor   The conductor used

to connect the grounding (earthing) electrode(s) to the equipment-
grounding (bonding) conductor, to the neutral (grounded) conductor, or
to both in accordance with Arts. 250.66 and 250.142.

First service disconnect  The very first electrical panel that will

disconnect (turn off) the power coming in from the utility company.
Sometimes this term is used to describe the first electrical panel that
can turn off power on the secondary or low-voltage side of a
transformer.

This provision is of course only applicable to those DC systems that must be

grounded in accordance with Art. 250.162.

11.7. 250.169. UNGROUNDED DIRECT CURRENT SEPARATELY

DERIVED SYSTEMS

This section tells us that ungrounded DC separately derived systems, such as

stand-alone DC generators and solar panels, must have a grounding electrode
conductor and a grounding electrode that complies with Part III of NEC Art. 250.

In other words, any DC stand-alone separately derived system, whether it is a

grounded electrical system or not, must be connected to earth via a qualified
grounding electrode.
Additionally, all non-current-carrying exposed metal parts must also be
connected to ground via the grounding electrode conductor, just as in a standard
AC system. This includes the first service disconnect and the metal enclosure of
the separately derived DC supply source.

Separately derived system(s)  A premises wiring system whose

power is derived from a source of electrical energy other than a (utility)
service. Examples include solar panels, generators, and wind turbines
that have no direct connection to another electrical source. Specifically,
the neutral conductor must not be solidly bonded to the neutrals of
other sources. This term is also used in regard to isolation and/or step-
down transformers that generate a distinct power source separate
from the utility.

Grounding (earthing) electrode  A device that establishes an

electrical connection to the earth/soil.

Grounding (earthing) electrode conductor   The conductor used

to connect the grounding (earthing) electrode(s) to the equipment-
grounding (bonding) conductor, to the neutral (grounded) conductor, or
to both in accordance with Arts. 250.66 and 250.142.

First service disconnect  The very first electrical panel that will

disconnect (turn off) the power coming in from the utility company.
Sometimes this term is used to describe the first electrical panel that
can turn off power on the secondary or low-voltage side of a
transformer.

Supply station, DC   A battery or a series of batteries, generator,

power supply, solar panel(s), or other device that provides DC electrical
power to a circuit.

An exception for vehicle-mounted and portable generators is made for this rule
and matches the rules found in Art. 250.34. Please see Art. 250.34 for more
information.

Citation
EXPORT
David R. Stockin: McGraw-Hill's National Electrical Code® 2014 Grounding and
Earthing Handbook. NEC 250 PART VIII: DIRECT CURRENT SYSTEMS, Chapter
(McGraw-Hill Professional, 2014), AccessEngineering
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