Conductors and Continuous Loads By Jim Pauley, P.E.—Square D Company November 1995, 011003503 The 1996 edition of the National Electrical Code (NEC) will contain some new language pertaining to the sizing of, conductors supplying continuous loads. NEW LANGUAGE FOR THE 1996 NEC Sections 210-22() and 220-3(a) have been revised in the 1996 NEC: “The minimum branch circuit conductor size, ‘without the application of any adjustment or correction factors, shall have an allowable ampacity equal to or greater than the noncontinuous load plus 125 percent of the continuous load.” The wording added to Section. 20-10(b) is identical, but “branch circuit” has been replaced with “feeder.” The addition of this wording clearly brings back into the NEC the requirement to base the conductor size on the noncontinuows load plus 125 percent of the continuous load. At first, the requirement appears to be severe. However, closer observation reveals that the additional wording simply “plugs a hole” in the present Code language on conductor sizing, The following ‘examples demonstrate use of the revisions made in Sections 210-22(c), 220-3(a), and 220-10(b). In all examples, the equipment terminations are assumed to be 75°C. Example 1: 1996 NEC. out derating, For Example 1, a feeder is sized using a continuous load of 200 amperes. Loed Conductor Allowable Ampacity Overcurrent Protective Device 200A 200x 1.25 = 250A 20x 1.25 = 250A, Using NEC Table 310-16, the minimum copper conductor size to reach the 250 ampere level would be a 250 kemil conductor. The 1996 NEC does not change the calculated load of 200 amperes. This is an important fact when considering additional derating factors for conduit fill or ambient temperature correction. —t— _, 260 ampore overcurrent doves a rd Lighting panebbosrd £200 ampere load 20 kemil copper conductor (75°C minimum inuiation) Figure 1: 196 NEC (assuming no derating) 0 1008 seyret Ritts ReservedNovember 1995 ADJUSTMENT AND CORRECTION FACTORS UNDER THE 1996 NEC ‘The rationale for the words “without any adjustment or correction factors” in the 1996 NEC text isto eliminate the need to “double derate” conductors. This occurs when ampacity correction factors for ambient temperature or adjustment factors for conduit fill must be applied in addition fo increasing the conductor size for continuous loads, Example 2: 1996 NEC with derating (using parameters from Example 1) ‘Assume that four current carrying conductors are now in the raceway. Note 8 of the “Notes to Ampacity Tables of (0 to 2000 Volts” requires that conductor ampacities be derated to 80% of the table value when four to six current carrying conductors are in the same raceway or cable. Assuming that the 250 kemil conductor used above is a 90°C insulated conductor, the derating is permitted to begin at the higher ampacity. In this case, the conductor has an allowable ampacity of 290 amperes based on the 90°C column in Table 310-16. The adjustment calculation would be as follows: 290A x .80 = 232 ampere allowable ampacity. At this point itis important to understand that the “calculated load,” as mentioned eatlier, has not changed. Recall that the overcurrent protective device in the example is a 250 ampere device. This 232 ampere conductor (250 kemil-50°C): + carties the calculated load of 200 amperes—Section 215-2 ‘is considered to be protected by the 250 ampere overcurrent clevice in accordance with Sections 215-3 and 240-3(b); the 232 ampere conductor is considered to be protected by the next larger standard size overcurrent device. ‘+ meets the minimum criteria of having an unadjusted ampacity based on 125 percent of the continuous load established by the new language in Section 220-10(b). ‘+ meets the temperature termination requirements in Section 110-14(c), 20 ampere overcurrent device Lgting panetboard 4 £200 arporo load 250 kemil copper conductor (00°C minima insviaton) Figure 2: 1996 NEC (assuming 80 percent derating) 2 6 190 square D Alt Rights ReservecNovember 1995, HOW DOES THE 1993 NEC HANDLE THE SAME EXAMPLES? ‘To understand the full impact of the 1996 change, the same examples will be reviewed using the rules in the 1993 NEC. Example 3: 1993 NEC without derating (using parameters from Example 1) In the first example where derating is not required, the following sequence of calculations can be made. ‘The conductor is sized to carry the tolal load without any factors for continuous loads. Load Conductor Allowable Ampacity Overcurrent Protective Device 200 200, 200 x 1.25 = 250 A To select a conductor for the 200 ampere load, NEC Table 310-16 is reviewed and reveals that a 3/0 AWG copper conductor has an allowable ampacity of 200 amperes at 75°C. However this conductor does not meet the requirements in Sections 215-3 and 240-3, which require protection by a 250 ampere overcurrent device. A 4/0 AWG copper conductor would be sufficient with a 75°C ampacity of 230 amperes. This conductor is considered. protected by a 250 ampere overcurrent device in accordance with Sections 215-3 and 240-3(b). However, the problem is that the permitted temperature limits of connected equipment are determined based on having a conductor sized at 125 percent for continuous loads to help “sink” the heat away from the equipment. With the 4/0 AWG copper conductor, the system is undersized by one conductor size, and increases in temperature at the ‘equipment terminations can occur. The term “system” is used because the conductor does not stand on its own; it is connected to equipment that depends upon its sizing, + __, 250 ampere overcurrent device Lighting paneacas 4 £200 ampore load 10 copper conautor (75°C minimum insulation) Figure 3: 1993 NEC (assuming no derating) © 1995 Square D AllFighls ReservedNovember 1995 Example 4: 1993 NEC with derating (using parameters from Example 1) ‘The 4/0 AWG 90°C insulated copper conductor has an allowable ampacity of 260 amperes. Adjusting this value 080 percent for the conduit fill results inthe following: 260 amperes x 80 = 208 amperes allowable ampacity. ‘This 208 ampere conductor does not meet the requirements in Section 215-3 and 240-3(b) for being protected by a 250 ampere overcurrent protective device. The next standard overcurrent device size above 208 amperes is 225 amperes. ‘not the 250 ampere device being used, so the conductor must be increased in size to meet the overcurrent protection criteria. A250 kamil copper conductor with a 90°C ampacity of 290 amperes would be acceptable as determined by the following: 290 amperes x 80 = 232 ampere allowable ampacity. + _, 250 ampere overcurent device Lighting pantooars 4 200 ampere load 250 kom copper conductor {eo"C mine rssaten) Figure 4: 1993 NEC (assuming 80 percent derating) HISTORICAL PERSPECTIVE In the 1984 edition of the Code, the rules required determination ofthe calculated load by adding the noncontinuous load plus 125 percent of the continuous load. The result was a calculated load with a “phantom” 25 percent adder included. Some facets of the industry disliked this requirement because the 25 percent ‘additional load did not actually exist. Through subsequent code cycles, the rules were ultimately changed to the text in the 1993 NEC, However, throughout all of the revisions of the rules, one critical factor was not reviewed— the dependence of the “system” on the size of the conductor. The changes in 1996 take this factor into account. 4 © 1005 square D All Rights ReservesNovember 1995 ‘The table below provides a quick summary of how the various code rules affect Examples 1 and 2. Table 1: Summary of Sizes from Various NEC Editions Using a 200 ampere continuous load, derating is calculated using an 80 percent factor because of four current carrying conductors in a raceway. Assumes 75°C terminations. NEC Example uses | Caloulated | ConductorSize | Overcurrent Edition derating? Load (copper) Device Size 1988 No 250A £250 komil 250A ‘Yes (80%) 250A 300 kemil (90°C)* 250A, 1990 No 200.4 4/0 AWG 250A ‘Yes (80%) 200A 250 kemil (90°C)* 250A 1996 No 200A £250 komil 250A ‘Yes (80%) 200A £250 komt (90°C)" 250A * Assumes 90°C insulated conductors are used and derated from the 90°C ampacity ‘SUMMARY ‘The new language in the 1996 NEC does not introduce a significant change in requirements. In all instances of both. past and present codes, the conductor has always been required to be protected in accordance with Article 240. This basic element required that conductors be increased in size to meet this rule. However, the 1996 language does solve the problem where a conductor was chosen “in between” overcurrent protective device sizes. This solution met the code language to be considered protected, but was undersized relative to temperature at the equipment terminals. ‘Many code users may ask “Why not just go back to previous code editions and require that continuous loads always be calculated at 125 percent?” The answer is in the derating examples shown above. If the “calculated load’ is increased by 25 percent, the derated ampacity of the conductor would be required to be at least this increased value. This resulted in “oversizing” the conductor more than necessary. 1D AURights Reserved — igSoUAce anal a regntredtacemara ot Sau D NEC Sn ar Caarc ose ae repstes wearavta cl ha Nara Fre Prtaton Asooton. [D] square D soem sg hit