Adigrat University, Department of Electrical & Computer

Engineering
Electrical Installation
Final Exam-Esque Procedures, Problems and Solutions

Determining Minimum number of Branch Circuits (NEC standard)

1a. First, calculate the minimum load by multiplying the area by the volt-ampere
given in NEC Table 220.12 for the occupancy.
1b. The connected load is calculated by multiplying the number of luminaires
(fixtures) by the luminaire (fixture)rating in volt-amperes. (if any load is
continuous multiply it by 125%)
1c. The grater of the minimum load and connected load becomes the calculated load
in volt-amperes.
1d. The volt-ampere of the connected loads are divided by the circuit voltage to
determine the calculated load in amperes.
1e. The calculated load in amperes is then divided by the branch circuit rating. That
quotient, rounded up if required to a whole number, indicates the number of
circuits.
Example 1:
Calculate the minimum number of lighting circuits for a 2400 sq. ft. dwelling. (note
General lighting outlets and receptacle outlets in residences are not considered to be
continuous loads)
From Table 220-3(a) of the NEC, the general lighting load for residences is
calculated assuming 3 VA/ft2. For this particular case: VA = 3 x 2400 = 7200.
The total load in amperes will be: 7200/120 = 60
The minimum number of 20 A circuits is: 60/20 = 3, or
The minimum number of 15 A circuits is: 60/15 = 4

Example 2: A total of 70 lamps is required an office area to be lighted. Each lamp

draws 2.1 A at 120 V. determine the minimum number of branch circuits required for the
lighting load. (Assume continuous loads).
Total load in ampere = 70*2.1 = 147 A
Apply the 125% factor to the load is continuous.
Load in A = 147*1.25 = 183.75 A
# of inimum branch circuits (rated 20 A) = 183.75 A/20 = 9.1875
Rounding up this number, the minimum number branch circuits required are 10.
 Selection of Conductor Sizes and Overcurrent Protection

Cable (or conductor) sizing is the process of selecting appropriate sizes for electrical
power cable conductors. Cable sizes are typically described in terms of cross-sectional
area, American Wire Gauge (AWG) or kcmil, or mm 2 depending on geographic region.

The proper sizing of cables is important to ensure that the cable can:

Operate continuously under full load without being damaged

Provide the load with a suitable voltage (and avoid excessive voltage drops)
Withstand the worst short circuits currents flowing through the cable

Cable sizing methods do differ across international standards (e.g. IEC, NEC, BS, etc)
and some standards emphasize certain things over others. However the general
principles that underpin all cable sizing calculation do not change.
When sizing a cable, the following general process is typically followed:
Gather data about the cable, its installation conditions, the load that it will carry,
etc
Determine the minimum cable size based on ampacity (continuous current
carrying capacity)
Determine the minimum cable size based on grouping, temperature of the
environment, and voltage drop considerations

Sizing conductors: BS standard (IEE Wiring Regulations 16 th edition)

When sizing cables for non-motor loads, the upstream protective device (fuse or circuit
breaker) is typically selected to also protect the cable against damage from selected to
exceed the full load current, but not exceed the cable's installed current rating, i.e. this
inequality must be met:
Definition and simple calculation of voltage drop
Voltage drop information for installation cables is given in BS 7671 Appendix 4 tables
expressed in millivolts for a current of one amp for one metre of the cable.

Example:
Sizing conductors: NEC standard
Branch-circuit conductors must be capable of carrying the load connected to the circuit.
They also must be sized large enough to reduce the circuits voltage drop when it
becomes necessary. The conductors also must have the capacity to handle adjustment
factors and correction factors if one or both of these conditions should occur. Any or all
of these conditions can occur, and it is highly advisable to recognize such problems and
size the conductors accordingly.

1. Determine the design current

2. Select the rating of the protection (The overcurrent device must have a rating not
less than the non-continuous load plus 1.25 times the continuous load)

3. Select the minimum ampacity of the branch-circuit/feeder conductor (when the

feeder supplies continuous and non-continuous loads, the minimum conductor
 size, before the application of any adjustment or correction factors, shall have an
allowable ampacity not less than the non-continuous load plus 125% of the
continuous load)

4. Apply correction or adjustment factors (to include effects of grouping,

temperature, etc.). Divide the ampacity obtained in step 3 by the correction
factors

5. Choose a cable size to suit the current determined in step4.

6. Check for voltage drop. Use the size of the conductor to the next larger size if
voltage drop requirement is not satisfied.

Examples:

Example1: What conductor size and OCPD are required for a 30 ampere, non-
continuous load, at a 42C (108F) ambient temperature, using THHN/THWN-2
conductors?

Example 2: What conductor size and OCPD are required for a 34 ampere, non-
continuous load, which does not include multiple receptacles for cord- and plug-
connected devices, at a 61C (142F) ambient temperature, using THHN/THWN-2
conductors?

Example 3: What conductor and OCPD are required for a 20 ampere, non-continuous
load, consisting of four (4) current-carrying conductors in a raceway, using THWN
conductors?
Example 4: Determine the circuit breaker rating and conductor size for a continuous
hard-wired lighting load determined to be 42 amperes, using THHN copper conductors,
with circuit breaker terminals rated at 75C.

Example 5: Ambient Temperature and More Than Three Conductors in a Raceway:

What conductor size and OCPD are required for eight THHN conductors in a raceway in
an indoor space at 48C (118F). The calculated load for each conductor is 195
amperes.
Feeder Size calculation
Example: A feeder supplies 92 amperes of continuous load and 70 amperes of
noncontinuous load. Determine the minimum rating of overcurrent device permitted to
protect this feeder.
Answer: The feeder consists of three type THHN copper current-carrying conductors in
raceway. The minimum rating of overcurrent device is required to be not smaller than
125% of the continuous load plus the non-continuous load. The calculation for this
feeder is as follows:
Feeder Size Calculation

The NEC in Article 220 gives a general method for computation of loads. For dwelling
units having the feeders conductors with an ampacity of 100 Amp or more, the following
procedure may be applied [NEC 220.30].

1 Calculate the lighting load as : (Area in ft2) x 3

2 Assign 1500 VA to each small-appliance circuit and to the laundry circuit
3 Include the volt-ampere rating of all appliances that are fastened in place
4 Include the largest of the various heating loads.
5 Add 1) through 3)
6 From 5) take the first 10kVA @ 100% and add the rest @ 40%
7 Add the heating load @ 100%. This will give the total volt-ampere necessary for
the service calculation
8 Calculate the ampacity from I = VA / V
9 Apply Table 310.15(B)(6) for the feeder selection and Table 250. 66 for the
ground conductor selection.

Steps:

Conductors for a branch-circuit or a feeder depend upon the load to be served and the
overcurrent device chosen for the circuit. Here is a suggested set of steps that can be
used to determine the minimum size of conductor for a branch circuit or a feeder where
the actual load to be served is known.
(1) If the overcurrent device rating is not known, then determine the minimum permitted
rating for the load before proceeding. (See the procedure below)
(2) Determine the minimum size of conductor permitted for the load. The procedure is
described in 210.19(A)(a) and 215.2(A)(1)(a). If there are no adjustment factors that are
required to be applied, then this is the minimum wire size permitted.
(3) If adjustment factors are required for the circuit then determine the factors that
must apply. Multiply these adjustment factors times the conductor ampacity found in the
table. The final adjusted ampacity must not be less than the actual circuit or feeder load
and it must also meet the overcurrent protection rules of 240.4. Keep selecting a larger
wire until these rules are satisfied. (See example on next page)

Overcurrent Device Selection: (1) The rule for determining the minimum size
overcurrent device permitted for a branch-circuit is found in 210.20(A). In the case of a
feeder the minimum overcurrent device rating is determined according to 215.3. In
either case the rule is the same. The overcurrent device must have a rating not less
than the noncontinuous load plus 1.25 times the continuous load.
Section 240.6(A) lists the standard ratings of overcurrent devices. Choose a rating that
is larger than the calculated load. The following example will illustrate the procedure.
Minimum Conductor Size for a Load: (2) The method to determine the minimum size
conductor for a specific load for a feeder is found in 215.2(A)(1)(a) and for a branch
circuit in 210.19(A)(1)(a). The rule is the same in both cases. The minimum conductor
size is not permitted to be smaller than the noncontinuous load plus 1.25 times the
continuous load. This minimum size is determined without any consideration of
adjustment or correction factors. If the wiring method is conductors in raceway or cable,
Table 310.15(B)(16) will be used to determine conductor ampacity. In most cases
conductor terminations are rated at 75EC. It is important to understand the rules of
110.14(C) in order to know whether the termination rating is 60EC or 75EC in cases
where the termination rating is not known. If the conductor insulation is 90EC rated,
but the terminations are 75EC rated, it is necessary to use the 75EC column of Table
310.15(B)(16). If the overcurrent device is rated greater than 100 amperes or the
conductor is size 1/0 AWG or larger, the terminations are rated 75EC unless otherwise
specified. For overcurrent devices 100 amperes and smaller or conductor sizes 1 AWG
and smaller, the terminations are rated at 60EC unless otherwise specified.
Adjustment Factors Applied to Wire Ampacity: (3) According to Table 310.15(B)(2)
(a), the ampacity values given in Table 310.15(B)(16) must be reduced to 80% of their
value if more than three but not more than six wires are in conduit or cable. If there are
more current carrying conductors in the conduit or cable, other adjustment factors must
apply. Table 310.15(B)(16) is based upon the wires placed in an ambient temperature
of 30EC. If the branch circuit or feeder run passes through an area where the
surrounding temperature is much higher than 30EC, then an adjustment in the ampacity
shown in Table 310.15(B)(16) is required. The temperature adjustment factors are
given in Table 310.15(B)(2)(a). When applying the adjustment factors to a portion of a
circuit, often the only limitation in that portion of the circuit is the conductor insulation.
Terminations are often not a factor when applying adjustment factors to the ampacity
found in Table 310.15(B)(16). If the wires have 90EC insulation, it is frequently
permitted to startthe adjustment using the ampacity for the size of wire in the 90EC
column of the ampacity table. Also, when finished applying the adjustment factors, the
wire ampacity is not permitted to be less than the actual load. For this comparison it is
not necessary to multiply the continuous load by 1.25.

Check the voltage drop

Protection techniques
The NEC generally requires conductors to be protected by a properly sized circuit
breaker or fuse with a rating not greater than the current-carrying capacity of the
conductors of the circuit. In other words, the overcurrent protection for the circuit and
equipment served must provide all necessary overcurrent protection, or a second stage
of protection must be installed. For example, if the OCPD for a circuit provides only
branch circuit, short circuit and ground-fault protection and does not protect from
overload conditions, such as in a motor circuit, overload protection is required as the
second stage of protection.
Steps to Select according to Ethiopian

Example 3 single-phase 240V 36A loads are to be supplied by means of 70C

thermoplastic PVC twin and earth cables having copper conductors, 25m in length, in an
area having an ambient temperature of 35C (Ca= 0.94). The cables are touching and
single-layer clipped to a non-metallic surface (for 3 circuits Cg=0.79). The overcurrent
device at the origin of the installation is a type-B MCB to BS EN 60898. Calculate the
minimum permissible cable size.

=-
Calculating Maximum Circuit Length. The maximum circuit length (one-way) for a given
conductor size and voltage drop is calculated by reorganizing the voltage drop equation and
solving for distance:
showing how these NEC provisions should be applied to determine conductor sizing and OCPD
rating.

Overcurrent Protection for Conductors

Conductors must be protected against overcur-rent by fuses or circuit breakers rated not more
than the ampacity of the conductors, Section 240.4. NEC 240.4(B) permits the use of the next
higher standard overcurrent device rating as shown in 240.6(A). This permission is granted only
when the overcurrent device is rated 800 amperes or less. For example, from Table 310.16, a 6
Type TW 140F (60C) conductor has an allowable ampacity of 55 amperes. In 240.6(A), we
find that the next higher standard size overcurrent device is 60 amperes. Nonstandard ampere
ratings of fuses and breakers are also permitted.
Branch-Circuit Rating
The rating of the overcurrent device (OCD) determines the rating of a branch circuit, as shown in
Figure 4-3.
 VOLTAGE DROP

Continuous Loads
The NEC defines continuous load as: a load where the maximum current is expected to
continuefor three hours or more. Continuous loads shall not exceed 80% of the rating of
the branch circuit. General lighting outlets and receptacle outlets in residences are not
considered to be continuous loads.

Example 5.1: Calculate the wire size for a branch circuit feeding a 5 kW water heater in a
dwelling.

The water heater is connected to 240 volts. The current is given by:

I = P/V = 5000/240 = 20.8 A

According to Table 310-16, No. 10 AWG copper conductors comply with the requirement.

Example 5.2: Calculate the wire size for a branch circuit feeding a 1.2 kW garbage disposal.

The garbage disposal is connected to 120 volts. The current is given by:

I = P/V = 1200/120 = 10 A

According to Table 310-16, No. 14 AWG copper conductors comply with the requirement.

Regional codes are in some cases more rigid than the NEC. As an example may be cited that
the South Florida Building Code establish the maximum number of outlets per circuit for
residential occupancies using the 12 points rule that assign one point for each light and two for
each receptacle. The combination of lights and receptacle connected to a circuit can not give
more than 12 points. Applying this rule, the actual number of general lighting circuits is always
much bigger than the previously obtained number.

Optional Method of Calculation:

5.12. For a 3600 sq. ft. unit with the following loads:

1500 VA dishwasher
1000 VA disposal
8000 VA range
5000 VA W.H.
4500 VA dryer
8500 VA A/C

Calculate:
 a) The feeder conductor size
b) The grounding copper conductor size

The maximum continuous load on an over current protection device rated 100 Amp is:
a) 80 Amp b) 88 Amp c) 90 Amp d) 100 Amp

What is the power loss in watts for a conductor that carries 30 Amp and has a voltage drop of 6
volts?
a) 180 b) 750 c) 200 d) 1020

A circuit with #12 THHN protected by a 15 O.C.P. is a 20 Amp circuit.

a) true b) false

Continuous loads shall not exceed _________ % of the branch circuit rating.
a) 125 b) 80 c) 75 d) a&b

Load Calculation:

The first step in our journey for a load calculation, per this requirement, must be to
examine each load in the system and determine if each is continuous (three hours
or more) or non-continuous. From 210.20(A), we understand that the 125% factor
applies only to continuous loads. The equation for calculating load current, which
will drive the selection of our conductors and which ultimately will drive the
selection of the OCPD, is as follows:

100% VS 80%: CHOOSING THE RIGHT

OCPD SOLUTION
We make decisions every day, both personally and professionally, with our checkbook
in mind. When decisions are made to value engineer or cost out a design to save
money on a project, attention is needed on the details; dot your is and cross your ts.
Sometimes you think you are saving money or time but in reality, the bottom line tells
you different. Were going to explore the topic of 100% versus 80% rated overcurrent
protection and build a foundation for the next project you design, install or inspect.
Remember the devil just could be in the details, but attention to the details will help
ensure a safe, economical installation.

The basic process to select the right overcurrent protective device (OCPD) for this discussion of
80% rated versus 100% rated, begins with a calculation of the load, includes a journey through
conductor selection based on the calculated load current, and ends with the right OCPD to
protect the conductor. As well see, when selecting an OCPD to be used at 100% of its current
rating, consideration must be given to the enclosure / distribution equipment in which the
breaker or fused switch is installed, as well as all associated listings.

In general, for all but motor overload protection, when an overcurrent device such as a molded
case circuit breaker (MCCB) or fuse is applied in an assembly, it must be sized at 125% of the
continuous load. This results in an overcurrent device being applied at 80% of its nameplate
rating. Lets do some math.

If the load on a branch circuit is a continuous load and calculated to be 100 A, NEC
210.20(A) requires the OCPD rating to be 125% of the calculated continuous load
current.

Where a branch circuit supplies continuous loads or any combination of continuous and
noncontinuous loads, the rating of the overcurrent device shall not be less than the
noncontinuous load plus 125 percent of the continuous load.

The OCPD device ampere rating for this example is calculated as follows:

OCPD Amp Rating =1.25 Continuous Load Amps =1.25 100A =125 A

The 80% number is the percentage of the OCPD amp rating that is the continuous load amps, in
this case, 100 Amps. 100 Amps is 80% of the 125 A rating of the OCPD as per the following
equation:

% of OCPD Rating =(Load Amps)/(OCPD Rating)100% =(100 A)/(125 A) 100% =80%

Applying an OCPD at 80% of its rating for continuous loads accounts for the resulting higher
ambient temperatures found when an overcurrent device is contained within an enclosure. This
also aligns with how an OCPD is tested by the standards which govern their performance.

For this above example, a 100% rated solution would have a 100 A breaker feeding this 100 A
calculated continuous load. Lets explore this further.

The Load Calculation

The load calculation is where it all begins and where the decision is made as to how the system
will be designed with regard to selecting equipment rated at 80% or 100%. In addition to the
important contents of Article 220, Branch-Circuit, Feeder, and Service Calculations, which will be
left to another article due to the simple fact that load calculations can be a book unto
themselves, we need to understand some basic terminology.

Step back and think about what a continuous and non-continuous load is. Determining the
difference between a continuous load and a non-continuous load is not as simple as it sounds.
To begin this discussion, open your Code book to Article 100 and review the definition of
Continuous Load. NEC 2014 tells us that a Continuous Load is a load where the maximum
current is expected to continue for 3 hours or more. For many loads, this will be a very
subjective effort of load analysis but for some the NEC is specific with this regard. Here are a
few examples of continuous loads specified in NEC 2014:

422.13 Storage-Type Water Heaters. A fixed storage-type water heater that has a capacity of
450 L (120 gals) or less shall be considered a continuous load for the purposes of sizing branch
circuits.

424.3 Branch Circuits. (B) Branch-Circuit Sizing. Fixed electric space-heating equipment and
motors shall be considered continuous load.

426.4 Continuous Load. Fixed outdoor electric deicing and snow-melting equipment shall be
considered as a continuous load.

427.4 Continuous Load. Fixed electric heating equipment for pipelines and vessels shall be
considered continuous load.

600.5 Branch Circuits.(B) Rating. Branch circuits that supply signs shall be rated in accordance
with 600.5(B)(1) or (B)(2) and shall be considered to be continuous loads for the purposes of
calculations.

625.41 Rating. Electric vehicle supply equipment shall have sufficient rating to supply the load
served. Electric vehicle charging loads shall be considered to be continuous loads for the
purposes of this article. Where an automatic load management system is used, the maximum
electric vehicle supply equipment load on a service and feeder shall be the maximum load
permitted by the automatic load management system.

Now that a continuous load and non-continuous load are crystal clear, we take our journey to
other appropriate Sections of the NEC for this discussion. The sections include:

Article 210, Branch Circuits

Section 210.19, Minimum Ampacity and Size
Section 210.20, Overcurrent Protection

Article 215, Feeders

Section 215.2, Minimum Rating and Size
Section 215.3, Overcurrent Protection
Article 230, Services
Section 230.42, Minimum Size and Rating
VII. Service Equipment Overcurrent Protection

As you can see, common to Services, Feeders and Branch Circuits is a section (Sections 210.19,
215.2 and 230.42) that focuses on sizing and rating of the portion of the circuit for which each
article is responsible. Article 210 is a good representative; the rest have similar language, and
so well begin here. Section 210.20(A) states the following:

210.20 Overcurrent Protection. (A) Continuous and Noncontinuous Loads. Where a

branch circuit supplies continuous loads or any combination of continuous and
noncontinuous loads, the rating of the overcurrent device shall not be less than the
noncontinuous load plus 125 percent of the continuous load.

The first step in our journey for a load calculation, per this requirement, must be to examine
each load in the system and determine if each is continuous (three hours or more) or non-
continuous. From 210.20(A), we understand that the 125% factor applies only to continuous
loads. The equation for calculating load current, which will drive the selection of our conductors
and which ultimately will drive the selection of the OCPD, is as follows:

Load Current =(Noncontinuous Load Amps) +(1.25 Continuous Load Amps)

This equation changes slightly when the decision is made to have a 100% rated system. A
review of the exception to the parent text of 210.20(A) reads as follows:

Exception: Where the assembly, including the overcurrent devices protecting the branch
circuit(s), is listed for operation at 100 percent of its rating, the ampere rating of the overcurrent
device shall be permitted to be not less than the sum of the continuous load plus the
noncontinuous load.

Based on the language in this exception, the load current is calculated for a 100% rated system
based on the following equation:

Load Current =Noncontinuous Load Amps +Continuous Load Amps

Youll note the missing 1.25 multiplying factor in the above equation. From this calculated load
current through the selection of conductor and OCPD, the process is exactly the same as that
for the 80% rated system.

Lets move on in our journey to conductor selection.

Load Current =(Noncontinuous Load Amps) +(1.25 Continuous Load Amps)

Conductor Selection
The selection of the conductor is based upon the calculated load current previously discussed.
As always, Chapters 1 4 of the NEC apply generally so we cant forget about the details related
to adjusting conductor ampacity and more. But for now, our journey takes us to Article 310 for
conductor selection, specifically Table 310.15(B)(16) of NEC 2014. Because we have a calculated
load current, whether it be based on an 80% or 100% of continuous load consideration, the
selection process for the conductor is now as routine as it gets with all of the details around the
environment and methods used to install the conductors.

Lets use some examples to describe the process for selecting the conductor for the
application. As noted above, this is driven by the load calculation. With this in mind, lets use
the following examples.

Example 1: The load on the branch circuit is a continuous 300 Amp load.

(80% Rated Design)

Load Current = (Noncontinuous Load Amps) +(1.25 Continuous Load Amps)

Load Current = 1.25 300 A = 375 A

The conductor size is selected from Table 310.15(B)(16). Using the 75oC column of this table
puts us into a 500 MCM conductor rated to carry 380 A.

A standard (80%-rated) circuit breaker rated at 400 amperes would be used.

(100% Rated Design)

Load Current =(Noncontinuous Load Amps) + (Continuous Load Amps)

Load Current = 300 A

The conductor size is selected from Table 310.15(B)(16). Using the 75oC column of this table
puts us into a 350 MCM conductor rated to carry 310 A.

A 100%-rated circuit breaker rated at 300 amperes would be used.

Example 2: The load on the feeder is comprised of a 200 Amp continuous load and 100
Amps of the noncontinuous load.

(80% Rated Design)

Load Current =(Noncontinuous Load Amps) +(1.25 Continuous Load Amps) Load Current =
100 A + (1.25 200 A) = 350 A

The conductor size is selected from Table 310.15(B)(16). Using the 75oC column of this table
puts us into two 2/0 conductors or one 500 MCM conductor.

A standard (80%-rated) circuit breaker rated at 350 amperes would be used.

(100% Rated Design)

Load Current =(Noncontinuous Load Amps) +(Continuous Load Amps) Load Current =100 A + 200 A =
300 A

The conductor size is selected from Table 310.15(B)(16). Using the 75oC column of this table
puts us into two 1/0 conductors or one 350 MCM conductor.

A 100%-rated circuit breaker rated at 300 amperes would be used.

OCPD Selection

Now that we have a conductor selected, the OCPD is selected to ensure the protection of the
conductor. The exception that permits sizing the OCPD for 100% of the continuous load plus
the noncontinuous load reads as follows:

Exception: Where the assembly, including the overcurrent devices protecting the branch
circuit(s), is listed for operation at 100 percent of its rating, the ampere rating of the overcurrent
device shall be permitted to be not less than the sum of the continuous load plus the
noncontinuous load.

These words, or some form thereof, can be found in each of the key articles mentioned above
for branch circuits, feeders, and services. Notice that the exception refers to the OCPD and the
assembly in which they are installed. Therefore, it is important to understand how an OCPD is
tested per its UL listing.

The following text is taken from UL Standard 489, Molded-Case Circuit Breakers, Molded-Case
Switches and Circuit-Breaker Enclosures.

9.1.4.4 A circuit breaker, having a frame size of 250 A or greater, or a multi-pole type of any
ampere rating rated over 250 V; and intended for continuous operation at 100 percent of
rating, shall be marked: Suitable for continuous operation at 100 percent of rating only if used
in a circuit breaker enclosure Type (Cat. No.) ____ or in a cubicle space ___ by ___ by ___ mm
(inches). Equivalent wording shall be permitted. Location Category C. The blanks are to be filled
in with the minimum dimensions.

This paragraph enlightens us to some important details.

1. 100% rated solutions for a circuit breaker will have a frame size no smaller than 250
Amps at 250 volts and below, or any case size for multi-pole circuit breaker with a voltage
greater than 250 V. Applications where the OCPD frame size is smaller than 250 Amps at 250
volts and less must utilize the circuit breaker at 80% of its amp rating (except for motor
overload protection).

2. The circuit breaker will be marked with a specific enclosure catalog number or minimum
dimensions of the enclosure. This tells us that we cant just swap out a circuit breaker with
one that is rated to handle 100% of its rating for continuous loads; consideration has to be
given to what enclosure in which the device is installed. It is not always possible to replace a
standard-rated circuit breaker with a 100%-rated circuit breaker and obtain a 100% rating
for the application.

There are also requirements that pertain to the enclosure for 100% rated applications as
demonstrated by Section 7.1.4.1.19 of UL 489 which states the following:

7.1.4.1.19 For the 100 percent rated test, a circuit breaker shall be connected with copper bus
bars if the circuit breaker is intended for use with both bus bars and wiring terminals. Unless
the circuit breaker is marked to indicate otherwise, the bus bars shall have a cross section of
1.55 A/mm2 (1000 A/in2) for ratings less than 1600 A. For ratings of 1600 A and higher, the bus
bar shall be in accordance with Table 7.1.4.1.3. If the circuit breaker is intended only for use
with wiring terminals, the test shall be conducted with insulated conductors, as specified in
7.1.4.1.15. The bus bars or cable shall be at least 1.219 m (4 feet) long. The test shall be
permitted to be repeated using insulated cable for a circuit breaker intended for use with both
bus bars and wiring terminals.

Not only the material of bus bars but also the dimensions are specific for these applications.
Manufacturers will help with what can and cannot be achieved with their equipment. It is
important not to violate the listing of the solution and, as always, the devil is in the details with
this regard.

Closing Remarks

The use of circuit breakers and fused switches is strictly controlled by the NEC and the UL
standards governing the circuit breakers, fused switches, and equipment into which they are
installed. There are times when it might be economically advantageous to utilize the devices at
100% of their ratings, but all is must be dotted and ts crossed. In this article, weve looked only
at the source side of the circuit. In order to complete the analysis, the equipment being
supplied must also be investigated to determine if it can be supplied with the often smaller
cables associated with the 100% rated circuit breakers or fused switches.

Circuit protection

OCPDs come in standard sizes, which are listed in 240.6. When you size conductor OCPDs,
you're trying to determine which of these standard sizes to use. Begin this sizing by
determining the conductor ampacity and then making ampacity adjustments specified in
310.15 [240.4].

Small conductors

Unless specifically permitted in 240.4(E) or (G), overcurrent protection must not exceed
(after ampacity adjustment and/or correction):

15A for 14 AWG copper.

15A for 12 AWG aluminum.

20A for 12 AWG copper.

25A for 10 AWG aluminum.

30A for 10 AWG copper.

In this practical example we are going to calculate the size of a cable using ElectricalDesign. The
calculation steps and methodology according to BS 7671 are outlined.

Methodology outline

1. Select cable type and installation method

2. Check overload protection (if required)

3. Calculate design current Ib

 4. Select protective device rating

5. Establish:

o Ca

o Cg

o Ci and Cf (where applicable)

6. Calculate

7. Check:

o Voltage drop

o Size for short-circuit

o Size for disconnection times

8. Determine cable size

Requirements, data

A 50kW, 3 phase load at 0.8 power factor.

The load is to be supplied by a NYY cable running on a perforated cable tray for 50m,
together with 6 other similar cables in touch.

Overload protection is to be provided by a MCCB. Zc is given as 0.15 Ohms.

It is assumed that the grouped cables may be subject to simultaneous overload (note
however that this is very unlikeley)

VI=400V
 Solution, Step 1, Set Low Voltage network
parameters
The parameters of low-voltage are defined in the image below

The first parameter is the phase-to-phase voltage and is set to 400V

Solution, Step 2, Define load properties,

Calculate design current I b
In the main switchboard add a new circuit that supplies the load e.g. Air-Handling Unit with the
following properties

Ib is calculated using the formula:

kW
Ib= 1000 (amps)
3 VI pf

where:

Ib is the design current of the circuit

Vl is the line voltage

pf is the power factor cos

 kW is the load power in kilowatts

hence,

50
Ib= = 90.2 A
3 400 0.8
Step 3, Selection of cable type and
installation method, Establish C a, Cg, Ci & Cc

1 Selection of cable type and installation

method
From the combo box on the left-top select a power cable type E1VV with PVC insulation and copper
conductors.

Ca is the correction factor for ambient temperature.

Since no ambient temperature is given (as is typically the case) we will assume an ambient
temperature of 30C. This is higher than is likely, and is conservative for cable selection purposes.

Hence from Table 4B1 of BS 7671: 2008 Ca = 1

Cg is correction factor for grouping (Table 4C of BS 7671: 2008)

From Table 4C1 for a group of 7 cables single layer multicore on a perforated cable tray, C g = 0.73

Ci is correction factor for conductors surrounded by thermal insulation.

The cables are not surrounded by insulation so Ci =1

Cc is a correction factor for the installation conditions (Table 4B3) and for use when overload
protection is being provided by overcurrent devices with fusing factors greater than 1.45 e.g. C c =
0.725 for semi-enclosed fuses to BS 3036.

The fuse is BS 88 and the cable is not laid underground in this section of the cable route so C c = 1
Step 4, Select type of overcurrent device
Step 5, Select protective device rating
 Step 6, Select protective device rating
Where overload protection is required:

In Ib

where:

Ib is the design current of the circuit

In is the nominal current or current setting of the protective device

The smallest protective device greater than 90.2 A is a 100 A overcurrent device BS 88 fuse;
thus In = 100 A.

2 Check if overload is required

As the cable is grouped with 6 other similar cables overload protection is required.

6 Calculate
In 100
It and hence, It 137 A.
Ca Cg Ci Cc 1 0.73 1 1

7 Check
7.1 Check voltage drop
Manual calculations of Ct can be tedious. The following graph provides a quick and convenient way
of avoiding them. The graph can be used to correct tabulated (mV/A/m) values and can be applied to
all cables under 16 mm and to the tabulated resistive component, (mV/A/m)r, for larger cables. The
graph is accurate where grouping factor is one and, for the buried cable portion, C g, Ci and Cc are =
1. Thus, from the graph we get a reduction factor (equivalent to C t) of 0.9; this is the same as the
value calculated above.

Reduction factors for thermoplastic cables (PVC)

The fault current (in this case an earth fault current) is fi rst calculated using the earth fault loop
impedance. Strictly speaking calculations need to be carried out at the upstream and downstream
ends of the cable but for illustration purposes, both will be carried out here (often a high loop
impedance and lower fault current can let through more energy).

At distribution board outgoing terminals assuming a fault

U0
If=
Ze
Note that Ze here is the earth fault loop impedance at the distribution board, in our simplifi ed
example it is also the external ELI.

230
If= = 1533 amps,
0.15

and from graph Figure 3.3B of BS 7671: 2008, disconnection time, t = 0.1 seconds. Note this fi gure
would be lower if the British Standard or manufacturers data were used and the disconnection time
would be 0.04 seconds, but we will proceed with 0.1 seconds. k from Table 54.4 is 51.

At load assuming a fault:

U0
If=
Zs

Note Zs here is the total earth fault loop impedance at the load end of the radial circuit. Using Table
4.5 of Appendix 4 of this book, the cable loop impedance, to be added to the external loop
impedance is:

R1 + R2 (ohms per km) L 2.19 100

= = 0.219 ohms
1000 1000

Total ELI, Zs = Ze + (R1 + R2 ) = 0.15 + 0.219 = 0.369 ohms.

230
If= = 623 amps,
0.369

and from graph Figure 3.3B of BS 7671: 2008, disconnection time, t = 2.8 seconds.
From Table 10.1, it can be seen that a 50 mm 4-core armoured cable, the csa of the armouring is
122 mm.

(i) Size using Table 54.7, then

k1 S
Minimum area of protective conductor
k2 2

from Table 54.2 of BS 7671: 2008

115 70
Minimum area of protective conductor 78.9 mm
51 2
TiSoft, 2017-01-26 08:01:45

The National Electrical Code (NEC or NFPA-70) is part of the National Fire Protection
Association, addresses proper electrical systems and equipment installation to protect people and
property from hazards arising from the use of electricity in buildings and structures in the USA.
Many local and municipal codes adopted the NEC and practically is used as a mandatory body as
part of the building code in the USA. The NEC is heavily tied with the insurance industry.
However, the NEC do not have jurisdiction for application in the power industry since all are self-
insured and have qualified personnel.
The NEC covers:
1. Installations of electric conductors and equipment within or on public and private buildings or
other structures, including mobile homes, recreational vehicles, and floating buildings; and other
premises such as yards, carnivals, parking lots, and industrial substations.
2. Installations of conductors and equipment that connect to the supply of electricity.
3. Installations of other outside conductors and equipment on the premises.
4. Installations of optical fiber cable.
5. Installations in buildings used by the electric utility, such as office buildings, warehouses,
garages, machine shops, and recreational buildings that are not an integral part of a generating
plant, substation, or control center.
If the facility is designed and build for a consulting firm for a private industry the NEC may be
considered under the jurisdiction of the NEC in most cases.

The Institute of Electrical and Electronics Engineers (IEEE) is a world technical

professional society with presence in 150 countries. Its mission is to promote the development of
electro-technology and allied sciences, the application of those technologies for the benefit of
humanity, the advancement of the profession, and the well-being of its Members.
Today, the IEEE is a leading authority in areas ranging from aerospace, computers and
communications to biomedical technology, electric power and consumer electronics with
activities.
Many of the standards are joined produced with ANSI (American National Standard Institute) and
in general are a suggested guide that is not mandatory by itseft unless required by the project
specification or adopted by an authority with jurisdiction over the subject matter application.
The International Electrotechnical Commission (IEC) is a similar organization to the IEEE
and primarily covers Europe and many other countries around the world. There is some
differences in engineering application with the IEEE/ANSI marketplace. However, there is
significant effort to homogenize both IEC & IEEE standards