SIZING BASIC CIRCUITS

BRANCH CIRCUIT WIRING FUNDAMENTALS

1. What is a branch circuit? (PEC 2009 ART 2.10)
The circuit conductors between the final
overcurrent device protecting the circuit
and the outlet.
a. Single phase branch circuit -
two wires + ground (commonly called
single phase 3 wires)
b. Three phase branch circuit three wires
+ neutral wire +ground wire ( commonly
called 3phase 5 wires)


Four Categories
Branch Circuit, Appliance
A branch circuit that supplies energy to one
or more outlets to which appliances are to be
connected and that has no permanently
connected luminaires (lighting fixtures) that
are not part of an appliance



Branch Circuit, General Purpose A
branch circuit that supplies two or more
receptacles or outlets for lighting and
appliances.




Branch Circuit, Individual- A branch
circuit that supplies only one utilization
equipment

Branch Circuit, Multiwire A branch
circuit that consists of two or more
ungrounded conductors that have voltage
between them, and a grounded conductor
that has equal voltage between it and each
ungrounded conductor of the circuit and
that is connected to the neutral or
grounded conductor of the system
2. Relevant Code Requirements
a. The ampacity of branch circuit conductors must not be less than the
maximum load to be served (PEC ART 2.10.2.1)

b. The maximum load to be served by the branch circuit conductors
when supplying two or more receptacles must not be more than 80%
of the ampacity of the conductors. (PEC ART2.10.2.3 (a), (b) ,(c) )
Table 2.10.2.3(b)2

c. The rating of a branch circuit is established or defined by the rating or
setting of its protective device. (PEC ART2.10.2.2 (a) thru (d)

d. The ampacity of the branch circuit conductors must not be less than
the rating of the branch circuit.

e. The total load of on any overcurrent device in a panelboard must not
exceed 80%of the rating of the overcurrent device.


Relevant Code Requirements (continuation)
f. Circuit conductors shall be protected against over- current in
accordance to their ampacities, but where the ampacity of the
conductor does not correspond with the standard ampere rating of a
fuse or circuit breaker, the next higher rating shall be permitted only if
this rating does not exceed 800 amperes (PEC ART 2.40.1.4)

g. The normal ampacities of conductors in cable or raceways are given
in PEC Table 3.10.1.16 copper and aluminum based on a 30
o
C ambient
temperature. For ambient temperature over or under 30
o
C, correction
factors must be considered. (to be found just below Table 3.10.1.16)

h. These normal ampacities may have to be reduced or derated where
there are more than three conductors in a cable or raceway. This means
a change in ampacities of circuit conductors (Table3.10.1.15(b)(2)a)

i. The current permitted to be carried by the branch circuit may have to
be reduced if the load is continuous. This does not mean a change in
the ampacities of the conductor but the rule refers to a limit of the load
to be carried by the conductors.
j. Continuous load refers to a load that operates for three hours or
more such as store lighting, office lighting and similar lighting loads.
k. Overcurrent protection for any single non- motor operated appliance
with ratings of 10 amperes or more must not be more than 150%of its
ampere rating.
l. General purpose receptacle outlet other than dwelling shall be taken
as a load of 180va for each single or for each multiple receptacle on
one yoke. (ART 2.20(k))



20Amps Circuit Breaker

3.5mm2 THW, ampacity is 20A

Case 1:
The circuit is in accordance with the code requirement. The
rating of this circuit is 20 Amperes. The load therefore
must be only 16A maximum allowed by the code
16 amps maximum continuous load
Lighting outlets
20Amps Circuit Breaker

2.0mm2 THWampacity is 15A

Case 2:
The circuit is in violation of the code requirement. The
rating of this circuit is greater than the ampacity of the
circuit conductors. The conductors will be overloaded even
before the overcurrent device works.
12 amps maximum continuous load
Lighting outlets
20Amps Circuit Breaker

8mm2 THW, ampacity is 40A

Case 3:
The circuit is in accordance with the code requirement. The
rating of this circuit is 20 amperes not 40 amperes. The
circuit should be loaded continously at 16 amperes
maximum
16 amps maximum continuous load
Lighting outlets
Number of Current carrying
Conductors
%Values in Tables 3.10.1.16-19
as adjusted for ambient
temperature if Necessary

4 to 6 80%
7 to 9 70%
10-20 50%
21-30 45%
31-40 40%
41 and above 35%
TABLE 3.10.1.15(B)(2)A Adjustment Factors for More than
Three current Carrying Conductors in a Raceway or Cable
3. DERATING CONDUCTOR AMPACITIES
a. The preceding illustrations are true if the wires are placed in conduits
not exceeding 3 current- carrying conductors in ambient temperature
of 30
o
C.

Typical Circuit Distribution in a Panelboard

In this example the ampacity of 8 of # 3.5MM2THW
conductors (20 amps) has to be derated to 70%
or 14 amps. Correspondingly the circuit protection
shall be resized to 15 amps based on the new
ampacity of 14 amps



Notes: Limiting the load to 80%for being continous load
(office lighting loads that operate for three hours or more
Must not be construed as a change in ampacity of the
Circuit conductors
Eight #3.5MM2THW
Cu circuit
conductors serving
continuous loads



Derated ampacity
= 20 x 0.70 x 0.80
=11.2Amps
4. CORRECTION FACTORS IN TEMPERATURES OVER 30
o
C
a. On top of the derating factors due to the large number of
conductors in a conduit or cable, there is a correction to the conductor
ampacities when installed or operated at temperatures over or under
30
o
C.
b. In tropical countries like Philippine setting, especially circuits
installed in between ceiling and the roofing, the factor corresponding
31- 40 deg C has to be applied. Consideration must likewise to be
observed in hot rooms in industrial plants as boiler rooms, furnace
areas and the like.

5. CONDUCTOR AMPACITY REQUIREMENTS
Example 1 Whats the circuit ampacity for three 30mm
2
THHN
conductors run in a raceway through the ambient temperatures zones
as shown in the figure

a) 115 amps
b) 110 amps
c) 120 amps
d) 100 amps


A
B C
D
Temp =28
o
C
1.00 correction
Temp =35
o
C
0.96 correction
Temp =22
o
C
1.04A correction
Temp =45
o
C
0.87correction
115A 110A 120A
100A
Ambient temperature ampacity
adjustment for 30mm
2
THHN (rated
115A)
The answer is d) 100. The ampacity for 30mm
2
THHN (90
o
C is
115amps, but the correction factors of table reduce the conductor
ampacity to only 100A ( 115amps x 0.87= 100)

Note: Where more than one calculated or adjusted ampacities
could apply to a given circuit length, the lowest ampacity must be
used for the entire circuit in calculations.
90
o
C conductor
6. CIRCUIT SIZING EXERCISES

Example 1:
A single phase circuit is to be wired in 75
o
C THW copper wire
dedicatedly installed inside a conduit in an area with an ambient
temperature of 36
o
C . If the circuit is supposed to carry 135 amps non-
continuous load current, what is the minimum size of wire and the
circuit overcurrent protection?

Answer:
a) Derating factor for 2 wires in a conduit = 100%
b) Correction factor, 36
o
C ambient temperature =88%
c) Non- continuous loading factor = 100%

Conductor size = 135A / (1.0 x 0.88 x 1.0)
Conductor size = 153.4 amps

Use 60mm
2
THW, Ampacity = 160 amps (Table 3.10.1.16 p. 350)
Derated ampacity = 160A x 0.88 = 141Amps

Use 150Amps standard rated MCCB

Example 2:
There are 2 single phase circuit to be wired in 75
o
C THW copper wire
installed inside a conduit in an area with an ambient temperature of 36
o
C . If
each circuit is designed to carry 135 amps continuous load current, what is
the minimum size of wire and the circuit overcurrent protection for each
circuit?

The branch circuit OCPD (or conductor) must have a rating of not less than
the noncontinupus load plus 125%of the continuous load before applying an
ampacity adjustment factor. {Articles 2.10.1.1(a) and 2.10.2.2(a)}

Answer:
a) Derating factor for 4 wires in a conduit = 80%(Table 3.10.1.15)
b) Correction factor, 36
o
C ambient temperature =88%
c) Continuous load limitation = 80%
Size of each conductor shall be:
Conductor size = 135A / (0.8 x 0.88 x 0.80)
Conductor size = 239.7 amps
Use 125mm
2
THW, Ampacity = 255 amps (Table 3.10.1.16 p. 350)
Derated ampacity = 255A x 0.8 x0.88 = 179.5Amps
(Note: 80%load limitation for continuous loads is not a derating factor)
Use 175Amps standard rated MCCB

Example 3:
Four single phase circuits are to be wired in 75
o
CTHW copper wire inside a
conduit passing through an area with an ambient temperature of 45
o
C . If
each circuit is designed to carry 12 amps continuous load current, what is
the minimum size of wire and the circuit overcurrent protection for each
circuit?

Answer:
a) Derating factor for 8 wires in a conduit = 70%(Table 3.10.1.15)
b) Correction factor, 45
o
C ambient temperature =82%
c) Continuous load limitation = 80%

Size of each conductor shall be:
Conductor size = 12A / (0.7 x 0.82 x 0.80)
Conductor size = 26.13 amps

Use 5.5mm
2
THW, Ampacity = 35 amps (Table 3.10.1.16 p. 350)
Derated ampacity = 35A x 0.7 x0.82 = 20.09Amps

(Note: 80%load limitation for continuous loads is not a derating factor)

Use 20 Amps standard rated MCCB

WIRES AND CABLES
7. SIZING CONDUCTORS BASED ON TEMPERATURE RATING
Question : If the engineer wants to use a THW wire , then we refer to the
75oC column
YES
If the engineer wants to use a THHN wire , then we refer to the 90
o
C
column
NOT QUITE
Has anyone heard of operational problems with THHN wires & cables? The
problem is in the difference in temperature ratings from device terminals
to wire terminals when connected together.














POINTS TO REMEMBER:
1. For device or equipment terminals rated 100A or less, or for 2.0mm2-
38mm2conductors, terminal sizes shall be based on the 60
o
C temperature
rating ( Art 1.10.1.14(c) )

Ex. What size THHN conductor does the PEC require for a 50A circuit if the
terminals are not marked with a temperature rating?
a) 5.5mm2 b) 8mm2 c) 14mm2 d) any of these
Ans c) 14mm2 (70 amps) and not 8mm2 (55amps) shall be used because
conductor size must be selected on the 60
o
C terminal rating of the device not
the 90
o
C rating of the insulation



Ex. What size THHN conductor does the PEC require for a 50A circuit if the
terminals are marked for use on 75oC temperature rating?
a) 5.5mm2 b) 8mm2 c) 14mm2 d) any of these
Ans. b) 8mm2 (55amps) .Size the conductors to the 75oC terminal rating of
the device and not 90oC.

2. Circuits over 100A - unless the terminals are marked otherwise, or for
conductors larger than 38mm2 equipment / device terminals rated over100A
shall be sized according to 75
o
C temperature rating (Art. 1.10.1.14(c) )
Ex. What size THHN conductor is required to supply a 225amps feeder
a) 50mm2 b) 60mm2 c)80mm2 d)125mm2
Ans. 125mm2 (265Amps). Size the conductors to the 75oC terminal rating

3. What then is the purpose of 90
o
C wire if we can not use its higher
ampacity?
Its rating comes into play when
adjusting conductor ampacity for elevated ambient temperature
or when bundling more than three current carrying conductors
together (derating).
The advantage is that it can keep the designer from using a larger
wire which requires larger raceways, greater labor and increased
material cost.
To Review:

Important in the electrical & thermal relationship for circuit
components are the conductor size, rated ampacity, the insulation
temperature rating and the permissible connector device temperature
limits

For instance, the ampacity for a conductor with 90degC insulation
(THHN) is generally greater than of a conductor of the same size but
with 60degC (TW) insulation.

However, the greater ampacity of a THHN conductor with 90degC
insulation is not always permitted to be used due to limitations of the
terminal temperature rating and /or the requirements of the PEC.



EXAMPLE: FEEDER CONTINUOUS LOAD

The feeder circuit OCPD (or conductor) must have a rating of not less than
the noncontinupus load plus 125%of the continuous load before applying
an ampacity adjustment factor. {Articles 2.15.1.2(1) and 2.15.1.3}

1. What size of OCPD/feeder THHN conductor does the PEC require for a 104A
continuous load?
a. 150A -50mm2 c. 125A 30mm2
b. 150A- 38mm2 d. 125A 38mm2
Step 1 : The overcurrent protective device (OCPD) must have a rating of
not less than 125% of the continuous load.
Thus , 104 A x 1.25=130A
The nearest OCPD rating is 150A protection

Step 2: The feeder conductor must have an ampacity of not less than 125%
of the continuous load before any ampacity adjustment. Thus the
feeder must be : 104A x 1.25= 130A

38mm2THHN is rated 130A at 75 deg C and the 150A overcurrent protection
device can protect it.
The answer is (b), 150A OCPD with 38mm2 THHN

SIZING AND INSTALLING PARALLEL CONDUCTOR SETS

In the case of high ampacity feeders, one conductor per phase may not be practical. Under
these circumstances , two or more conductors per phase may be desirable or even
necessary. The objective is to keep the resistance of each parallel path equal so the load
current will divide equally on each wire of the set. The wires and terminations heat up
when they carry current; therefore the resistance changes when the temperature of the wire
and terminations changes. For these reasons, special requirements are necessary when
installing parallel sets of wires. The following is a summary of some special installation
rules for sets of multiple conductors for each ungrounded conductor and grounded
conductor.

1. Power conductors are permitted to be paralleled only for size 50mm2 (#1/0 AWG) or
larger, except for special applications.
2. All parallel conductors of the phase or neutral set shall be of the same length.
3. All conductors of the phase and neutral set shall be of the same material, cross
sectional area, and the same insulation type.
4. All conductors of a phase or neutral set shall be terminated in the same manner.
5. If run in more than one raceway, the raceways shall have the same physical properties,
and the same length, and shall be installed in the same manner
6. If more than one raceway is used, make sure each phase wire and neutral, if present, is
placed in each of the raceways to prevent eddy currents.
7. If an equipment grounding wire is present and there is more than one raceway, an
equipment grounding wire shall be in each raceway.



Example : Circuits with Overcurrent Protection Over 800A

If the circuit OCPD exceeds 800A, the circuit conductors must have an ampacity
not less than the rating of the OCPD {Art 2.40.1.4(c)}

Example : Feeder Continuous Load
1. What size feeder conductor does the PEC require for a 1200A service/feeder
paralleled in three raceways?
a. 200mm2 b. 300mm2 c. 250mm2 d. any of these

Step 1. Determine ampacity per parallel conductor, 1200/3 = 400A

Step 2. Select a conductor using Table 3.10.1.16 page 350 that has an ampacity of
435 at 75degC

A 325mm2 conductor (435 x 3 =1305A) is required arranged in three conduits
with three conductors per conduit. (470A is the ampacity of THHN at 90 degC)
But note that the 3//325mm2 THHN per phase in this case , is only seen at
1305A (435A x 3=1305A) ampacity basing at 75degC column.