4a LESSON 11 - WIRING METHODS 11.1 Introduction This lesson will be @ guide for the general rules in wiring and protection of conductors, and was primarily concerned with the correct sizing of circuits and the means of protecting them. This is very specific about conductors, cables, boxes, raceways, and fittings. It's also highly detailed about the installation and restrictions involved with wiring methods. The type of wiring method to be used depends on several factors: Code requirements, the environment, need, and cost are among them This lesson is really a modular assembly of articles, each detailing a specific area of an electrical installation. This article is primarily concerned with how to install, route, splice, protect, and secure conductors and raceways. How well an electrical practitioner conform to the requirements of the Code will generally be evident in the finished work, because many of the requirements tend to determine the appearance of the installation. Using the knowledge gained, it's often easy to spot electrical installation problems if you're looking for Code violations 11.2 CONDUCTORS Limitations (2) Voltage Wiring methods shall be used for 600 volts, nominal, or less. ( 3.0.1.2) (b) Temperature No conductor shall pe used in such a manner that its operating temperature exceeds that designated for the type of insulated conductor involved. In no case shall conductors be associated together in such a way, with respect to type of circuit, the wiring method employed, or the number of conductors, that the limiting temperature of any conductor is exceeded (3.10.1.10) Question: What is the corrected ampacity of 3/0 THHN/THWN conductors in a dry location if the ambient temperature is 108°F? Conductor Ampacity [90°C] = 2254 Correction Factor [Table 310.16] = 0.87 Corrected Ampacity = 225A x 0.87 Corrected Ampacity = 196AQuestion: What is the corrected ampacity of 3/0 THHN/THWN conductors in a wet location if the ambient temperature is 108°F? Conductor Ampacity [75°C] = 200A Correction Factor [Table 310.16] = 0.82 Corrected Ampacity = 200A x 0.82 Corrected Ampacity = 1644 (c) Conductors of the Same Circuit [3.0.1.3 (b) ] Alll conductors of the same circuit and, where used, the grounded conductor and all equipment grounding conductors and bonding conductors shall be contained within the same raceway, auxiliary gutter, cable tray, cable bus assembly, trench, cable, or cord, unless othenwise permitted elsewhere in the Code. (d) Conductors of Different Systems [3.0.1.3 (c) ] (1) 600 Volts, Nominal, or Less. Conductors of circuits rated 600 volts, nominal, or less, ac circuits, and de circuits shall be permitted to occupy the same equipment wiring enclosure, cable, or raceway. All conductors shall have an insulation rating equal to at least the maximum circuit voltage applied to any conductor within the enclosure, cable, or raceway Exception: For solar photovoltaic systems in accordance with 6.90.1.4(b) (2) Over 600 Volts, Nominal. Conductors of circuits rated over 600 volts, nominal shall not occupy the same eguipment wiring enclosure, cable, or raceway with conductors of circuits reted 600 volts, nominal, or less unless otherwise permitted 11.3 Protection Against Physical Damage [3.0.1.4] Where subject to physical damage, conductors shall be adequately protected, 14.4 Protection Against Corrosion and Deterioration [3.0.1.6] Metal raceways, cable trays, cablebus, auxiliary gutters, cable armor, boxes, cable sheathing, cabinets, elbows, couplings, fittings, supports, and support hardware shall be of materials suitable for the environment in which they are to be installed and shall be suitably protected against corrosion inside and outside (except threads at joints) by a coating of listed corrosion resistant material such as zinc, cadmium, or enamel.4s 11.5 Conductors with Other Systems. Raceways or cable trays containing electric conductors shall not contain any pipe, tube, or equal for steam, water, air, gas, drainage, or any service other than electrical. [ 3.0.1.8 ] 11.6 Electrical Continuity of Metal Raceways and Enclosures [ 3.0.1.0 J Metal raceways, cable armor, and other metal enclosures for conductors shall be metallically joined together into a continuous electric conductor and shall be connected to all boxes, fittings, and cabinets so as to provide effective electrical continuity. Uniess specifically permitted elsewhere in this Code, raceways and cable assemblies shall be mechanically secured lu boxes, fittings, cabinets, and other enclosures. 11.7 Securing and Supporting [3.0.1.17] Raceways, cable assemblies, boxes, cabinets, and fittings shall be securely fastened in place. 11.8 Conductors continuity [3.0.1.13(a) ] Conductors in raceways shall be continuous between outlets, boxes, devices, ‘and so forth. There shall be no splice or tap within a raceway unless permitted elsewhere in the Code 14.9 Number and Size of Conductors in Raceway [3.0.1.17] The number and size of conductors in any raceway shall not be more than will permit dissipation of the heat and ready installation or withdrawal of the conductors without damage to the conductors or to their insulation 14.10 Maximum Number of Conductors. The number of conductors installed shall not be greater than the number for which the raceway is desianes. The combined cross-sectional area of all conductors or cables shall not exceed forty percent (40%) of the cross-sectional area of the conduit46 11.11 OTHER CODE PROVISIONS: Conductor Material. Conductors in this article shall be of aluminum, copper-clad aluminum, or copper unless otherwise specified. Stranded Conductors. Where installed in raceways, conductors of size 8.0 mm? and larger shall be stranded. Conductors Grouped Together [3.0.1.20] Where conductors carrying alternating current are installed in metal enclosures or metal raceways, they shall be arranged so as to avoid heating the surrounding metal by induction. To accomplish this, all phase conductors and, where used, the grounded conductor and all equipment grounding conductors shall be grouped together. Conductors in Parallel [3.10.1.4] ‘Aluminum, copper-clad aluminum, or copper conductors of size 50 mm? and larger, comprising each phase, polarity, neutral, or grounded circuit conductor, shalll be permitted to be connected in parallel (electrically joined at both ends) Conductor Characteristics. When circuit conductors are runin parallel, the current must be evenly distributed between the individual parallel conductors by requiring all circuit conductors within a parallel set to: (1) Be the same length (2) Be made of the same conductor material (copper/aluminum). (3) Be the same size in circular mil area or mm ? (minimum 1/0 AWG or S0mm?). (4) Have the same insulation (like THHN) (5) Terminate in the same method (set screw versus compression). Length of Free Conductors at Outlets, Junctions, and Switch Points. At least 150 mm of free conductor, measured from the point in the box where it emerges from its raceway or cable sheath, shall be left af each outlet, junction, and switch point for splices or the connection of luminaires (fixtures) or devicesa7 Marking All conductors and cables shall be marked to indicate the following information. (1) The maximum rated voltage (2) The proper type letter or letters for the type of wire or cable as specified elsewhere in this Code (3) The manufacturer’s name, trademark, or other distinctive marking by which the organization responsible for the product can be readily identified (4) The size in millimeter square or millimeter diameter Conductor Bundle [3.10.1.15b] Where the number of current-carrying conductors in a raceway or cable exceeds three, or where single conductors or multi-conductor cables are installed without maintaining spacing for a contiriuous length longer than 600 mm (24), the allowable ampacity of each conductor, must be adjusted in accordance with the adjustment factors. Question: What is the adjusted ampacity of 3/0 THHN/THWN conductors in a dry location if the raceway contains a total of four current-carrying conductors? Table 310.16 ampacity if 3/0 THHN/THWN in a dry location is 2254 Adjustment Factor [Table 3.10.1.15(B)(2)(a)] = 0.80 Adjusted Ampacity = 225A x 0.80 Adjusted Ampacity = 180A Question: What is the adjusted ampacity of 3/0 THHN/THWN conductors in a wet ‘ocation if the raceway contains a total of four current-carrying conductors? Table 310.16 ampacity if 3/0 THHN/THWN in a wet location is 200A Adjustment Factor {Table 310.1.15(B)(2)(a)] = 0.80 Adjusted Ampacity = 200A x 0.80 Adjusted Ampacity = 1604 Locations [3.0.1.17] (1) Dry Locations. Insulated conductors and cables used in dry locations shall be any of the types identified in this Code.(2) Dry and Damp Locations. Insulated conductors and cables used in dry and damp locations shall be Types FEP, FEPB, MTW, PFA, RHH, RHW, RHW-2, SA, THHN, THW, THW-2, THHW, THHW-2. THWN, THWN-2, TW, XHH, XHHW, XHHW-2, Z, or Zw. (3) Wet Locations. Insulated conductors and cables used in wet locations shall be (1) Moisture-impervious metal-sheathed; (2) Types MTW, RHW, RHW-2, TW, THW, THW-2, THHW, THHW-2, THWN, THWN-2 XHHW, XHHW-2, ZW: or (3) Of a type listed for use in wet locations. Exposed to Direct Sunlight Insulated conductors or cables used where exposed to direct rays of the sun shall be of type listed or marked "sunlight resistant" Corrosive Conditions Conductors exposed to oils, greases, vapors, gases, fumes, liquids, or other substances having a deleterious effect on the conductor or insulation shall be of a type suitable for the application. Service drop Conductors a. Minimum Size The conductors shall not be smaller than 8.0 mm? (3.2 mm dia.) copper or 14 mm? aluminum or copper-clad aluminum. “b. Vertical Clearance from Ground [ 2.30.2.4 ] Service-drop conductors, where not in excess of 600 volts, nominal, shall have the following minimum clearance from final grade: (1) 3000 mm — at the etzctric service entrance to buildings, also at the lowest point of the drip loop of the building electnc entrance, and above areas or sidewalks accessible only to pedestrians, measured from final grade or other accessible surface only for service-drop cables supported on and cabled together with a grounded bare messenger where the voltage does not exceed 150 volts to ground (2) 3600 mm — over residential property and driveways, and those commercial areas ot subject to truck traffic where the voltage does not exceed 300 volts to grounda9 (3) 4500 mm — for those areas listed in the 3600 mm classification where the voltage exceeds 300 volts to ground (4) 5500 mm — over public streets, alleys, roads, parking areas subject to truck traffic, driveways on other than residential property, and other land such as cultivated, grazing, forest, and orchard Drip Loops 12.30.4.15 (8&9 )] Service-drop conductors and service-entrance conductors shall be arranged so that water will not enter service raceway or equipment. Drip loops shall be formed on individual conductors. To prevent the entrance of moisture, service-entrance conductors shall be connected to ths service-drop conductors either (1) below the level of the service head or (2) below the level of the termination of the service-entrance cable sheath. Grounding and Bonding 2.50.1.2] The following general requirements identify what grounding and bonding of electrical systems are required to accomplish (1) Electrical System Grounding. Electrical systems that are grounded shall be connected to earth in a manner that will limit the voltage imposed by lightning, line surges, or unintentional contact with higher-voltage lines and that will stabilize the voltage to earth during normal operation. (2) Grounding of Electrical Equipment. Conductive materials enclosing electrical conductors or equipment, or forming part of such equipment, shall be connected to earth so as to limit the voltage to ground on these materials. (3) Bonding of Electrical Equipment. Electrically conductive materials, such as metal water piping, metal gas piping, and structural steel members, that are likely to become energized shall be bonded as specified by this article to the supply system grounded conductor in a manner that establishes an effective path for fault current (4) Performance of Fault Current Path. The fault current path shall be permanent and electrically continuous, shall be capable of safely carrying the maximum fault ikely to be imposed on it, and shall have sufficiently low impedance to facilitate the operation of overcurrent devices under fault condition,so Connection of Grounding and Bonding Equipment [2.50.1.8] Grounding conductors and bonding jumpers shall be connected by exothermic welding, listed pressure connectors, listed clamps, or other listed means. Connection devices or fittings that depend solely on solder shall not be used. Sheet metal screws shall not be used to connect grounding conductors or connection devices to enclosures Conduit bends (Number in One Run) There shall not be more than the equivalent of four quarter bends (360 degrees total) between pull points, for example, conduit bodies and boxes. Spread of Fire or Products of Combustion. Electrical circuits and equipment must be installed in such a way that the spread of fire or products of combustion will not be substantially increased. Openings in fire- rated walls, floors, and ceilings for electrical equipment must be fire-stopped using methods approved by the authority having jurisdiction to maintain the fire-resistance rating of the fire-rated assembly Space inEnclosures — [3.73.1.7] Cabinets and cutout boxes shall have sufficient space to accommodate all conductors installed in them without crowding. Enclosures installed in wet locations shall be weatherproof. Classification of Panelboards [3.84.3.2] Panelboards shall be classified for the purposes of this article as either lighting and appliance branch circuit panelboards or power panelboards, based on their content (a) Lighting and Appliance Branch-Circuit Panelboard. A lighting and appliance branch-circuit panelboard is one having more than 10 percent of its overcurrent devices protecting lighting and appliance branch circuits. A lighting and appliance branch circuit is a branch circuit that has a connection to the neutral of the panelboard and that has. overcurrent protection of 30 amperes or less in one or more conductors. (b) Power Panelboard. A power panelboard is one having 10 percent or fewer of its overcurrent devices protecting lighting and appliance branch circuits.Number of Overcurrent Devices on One Panelboard = 3.84.3.3] Not more than 42 overcurrent devices (other than those provided for in the mains) of a lighting and eppliance branch-circuit panelboard shall be installed in any ‘one cabinet or cutout box. A lighting and appliance branch-circuit panelboard shall be provided with physical means to prevent the installation of more overcurrent devices than that number for which the panelboard was designed, rated, and approved. For the purposes oF this article, a 2-pole circuit breaker shall be considered two overcurrent devices, a 3-pole circuit breaker shall be considered three overcurrent devices. Panelboard Protection [3.84.3.4] Panelboard shall be protected on the supply side by an overcurrent protective device having a rating not greater than that of the panelboard. This overcurrent protective device shall be lozated within or at any point on the supply side of the panelboard. Number of Services [2.30.1.2] A building or other structure served shall be supplied by only one service unless permitted by the following: (a) Special Conditions. Additiunal services shall be permitted to supply the following (1) Fire pumps (2) Emergency systems (3) Legally required standby systems (4) Optional standby systems (5) Parallel power production systems (b) Special Occupancies. By special permission, additional services shall be permitted for either of the following (1) Multipie-occupaney buildings where there is no available space for service ‘equipment accessible to all occupants (2) Multiple-occupar cy building or group of single detached buildings owned/operatedimanaged by @ person or entity and spaces are available, a main service entrance and main service equipment shall be allowed to serve the main service equipment of each occupant and common loads , if any.52 (c) Capacity Requirements. Additional services shall be permitted under any of the following (1) Where the capacity requirements are in excess of 2000 amperes at a supply voltage of 600 volts or less (2) Where the load requirements of a single-phase installation are greater than the serving agency normally supplies through one service (a) Different Characteristics. Additional services shall be permitted for different voltages, frequencies, or phases, or for different uses, such as for different rate schedules. (e) Identification. Where a building or structure is supplied by more than one service, or any combination of branch circuits, feeders, and services, a permanent plaque or directory shall be installed at each service disconnect location denoting all other services, feeders, and branch circuits supplying that building or structure and the area served by each. One Building or Other Structure Not to Be Supplied Through Another [ 2.30.1.3 ] Service conductors supplying @ building or other structure shall not pass through the interior of another building or other structure. _ CORRECTION EACTORS Ambient For ambient temperatures siherthau 30°C (86°F), multiphy the allowable ampaciies shown above by the Ambient Temp, Temp. (() appropriate factor shown below, (A B 108 WO Lt 1 1 | iu au i 10 10) uy 1M A ite 1 Lo wt i wi ww O95 Li ‘st 0 a aT i OL a 43) OL 082 Og Ett) O38 Os, 8 Ost O75, 02 MA oa 08 4% Ou 06) 0% 31 = 458 | AL = Ost 1 td =| is Tt = im if a = = al 19.0%53 LESSON 12- BRANCH CIRCUIT Calculation 12.1 BRANCH CIRCUIT The Code defines Branch Circuit as "the circuit conductors between the final overcurrent device protecting the circuit and the outlet(s)." A conductor is a wire suitable for carrying an electric current. A stranded conductor is a conductor composed of a group of wires or of any combination of groups of wires. The wires in a stranded conductor are usually twisted together and not insulated from each other. A cable is either a stranded conductor (single-conductor cable) or a combination of conductors insulated from one another (multiple-conducior cable). The term "cable" is a general one and usually applies only to the larger sizes of conductors. Cables may be bare or insulated. Conductors are stranded mainly to increase their flexibility. 12.2 SELECTION OF WIRE SIZE Several factors must be considered in selecting the size of wire to be used for transmitting and distributing electric power. Having a good knowledge on conductors, reduces the danger of fires caused by the improper selection of wire sizes. Also economic aspect will not be compromised, danger of fires caused by the improper selection of wire sizes Wires can carry only a limited amount of current safely. If the current flowing through wire exceeds the current-carrying capacity of the wire, excess heat is generated. This heat may be great enough to burn off the insulation around the wire and start a fire The current rating of a cable or wire indicates the current capacity (ampacity ) that the wire or cable can safely carry continuously. If this limit, or current rating, is exceeded for a length of time, the heat generated may bum the insulation. The current rating of a wire is used to determine what size is needed for a given load, or current drain. The factors that determine the current rating of a wire are the conductor size, the location of the wire, the type of insulation, wiring method, and the length of the wire to be used54 12.3 CALCULATION OF BRANCH CIRCUIT LOADS (Not More Than 600 Volts) The PEC provides that "Branch-circuit conductors shall have an ampacity not less than the maximum load to be served. Where a branch circuit supplies continuous loads or any combination of continuous and noncontinuous loads, the minimum branch- circuit conductor size, before the application of any adjustment or correction factors, shall have an allowable ampacity not less than the noncontinuous load plus 125 percent (125%) of the continuous load." @ Rating. The rating for other than individual branch circuits shall be 15, 20, 30, 40, and 50 amperes. Where conductors of higher ampacity are used for any reason, the ampere rating or setting of the specified overcurrent device shall determine the circuit rating @ Permissible loads In no case shall the load exceed the branch circuit ampere rating. An individual branch circuit shall be permitted to supply any load for which itis rated @ 15A, 20A, and 30A Branch Circuit Arating of any utilization equipment shall not exceed eighty percent (80%) of the branch-circuit ampere rating @ Luminaires (Lighting Fixtures). An outlet supplying Iuminaire(s) [lighting fixture(s)] shall be calculated based on the maximum volt-ampere rating of the equipment and lamps for which the luminaire(s) [fixture(s)] is rated @ Receptacle Outlets. Receptacle outlets shall be calculated at not less than 180 VA for each single or for each multiple receptacle on one yoke. A single piece of equipment consisting of a multiple receptacle comprised of four or more receptacles shall be calculated at not less than 90 VA per receptacle.Specific Appliances or Loads ‘An outlet for a specific appliance or other load shall be computed based on the ampere rating of the appliance or load served. Branch Circuits Larger Than 50 Amperes. Branch circuits larger than 50 amperes shall supply only nonlighting outlet loads. Single Branch Circuit. For a dwelling unit having a floor area not more than 50sq.meters it shall be permitted to have a single 20A, 2-wire branch circuit provided that the total load shall not exceed 3,680 VA. 42.4 Overcurrent Protection (Not More Than 600 Volts) Branch circuit conductors and equipment shall be protected by overcurrent protective devices. The purpose of an overcurrent protective device (OCPD) is to protect the circuit wiring and devices and to some extent the equipment served by the circuit. The following Code references must be consulted when selecting an OCPD. EA continuous load is defined as one where the load is expected to operate for a period of 3 hours or more. Office and store lightings are common examples of continuous loads. PEC states that tne OCPD shall have a rating not less than the non-continuous load plus 125% of the continuous load © The rating of the OCPD becomes the rating of the branch circuit regardless of the conductor size or load type. Unless specifically permitted the overcurrent protection shall not exceed 15A for 2.0mm? , 20A for 3.5mm” , and 30A for 5.5mm? copper. @ If the ampacity of the conductor is between standard ampere ratings for overcurrent devices the next higher ampere rating fuse or circuit breaker issé permitted under specific conditions. These conditions include the rating if the circuit is 800 amperes or less. @ Standard Ampere Ratings. The standard ampere ratings for fuses and inverse time circuit breakers shall be considered 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 125, 150, 175, 200, 225, 260, 300, 350, 400, 450, 500, 600, 700, 800, 1000, 1200, 1600, 2000, 2500, 3000, 4000, 5000, and 6000 amperes. The use of fuses and inverse time circuit breakers with nonstandard ampere ratings shall be permitted,