NATIONAL ELECTRICAL CODE

Conductor Sizes Directly Related

to Terminal Temperature Ratings
The effect of reduced terminal temperature ratings on conductor ampacities

Eddie Guidry | Feb 25, 2016

Although the requirements for limiting the ampacities of conductors to that of the
terminal temperature ratings found in NEC Table 310.15(B)(16) has been clear in Sec.
110.14(C)(1) for many years (since the reference to the specific table was added several
Code cycles back), confusion still exists on what this Section means and how it affects
conductor sizes. Let’s try and clear the air a bit by reviewing a couple of real-world
examples of how to apply these Code requirements.
 Pho
to courtesy of Thomas

Example No. 1

The calculated minimum ampacity of a conductor is 200A. Type XHHW-2, 600V,

copper wire is being used on the circuit.  The parameters found at the top of Table
310.15(B)(16) are met in this case, so we can use the table values verbatim.

The circuit breaker is a thermal magnetic type rated 200A. The terminals on the breaker
are marked 75°C. Voltage drop isn’t an issue. No. 2/0 AWG conductors are chosen with
an ampacity of 195A. This is allowed in this case per Sec. 240.4(B) because we’ve met
conditions (1) through (3).

So, we have 195A wire connected to a 200A breaker. On the surface, this appears to be a
Code-compliant installation. However, since we’re using 90°C degree insulation, the
wire is rated at 195A, but per Sec. 110.14(C)(1) we can’t exceed the ampacity of the 75°C
column, which is only 175A in this case. Therefore, we have to go up in size with the
conductors to a rating of at least 200A in the 75°C column. In this case, we’d have to use
a minimum of No. 3/0 AWG, copper conductors.

Although in this specific example the increased size of conductors wasn’t extreme, let’s
take a look at another example where there is a large impact of the terminal ratings on
the minimum conductor size.

Example No. 2

The calculated minimum ampacity of a conductor is 1,000A. Type XHHW-2, 600V,

copper wire is being used on this circuit. The cables will be parallel, two conductors per
phase. The cables are installed in cable tray and comply with the requirements of Sec.
392.80(A)(2)(c). So, we can use the ampacity values found in Table 310.15(B)(17).

The 1,000A breaker has 90°C rated bus-type terminals on the breaker and 90°C rated
compression lugs on the cable, so this termination is rated for 90°C. But, keep in mind
that even though we initially thought we were allowed to use Table 310.15(B)(17), we’re
limited to the ampacities of Table 310.15(B)(16) for the breaker terminals.

Using Table 310.15(B)(17) alone, it looks like we could use two, parallel, 300kcmil
conductors per phase, which would give us the 1,000A of ampacity that we need. Now,
we look at Table 310.15(B)(16) values for the breaker because we must follow the
requirements of Sec. 110.14(C)(1). We find that to get a rating of 500A per conductor
(1,000A for the combination of the two parallel conductors), we’d have to use a
minimum of 700kcmil per each conductor. That’s a huge difference from the parallel
300kcmil wire that we initially thought we could use.

Lesson of the day

Always remember to keep the restrictions of the terminal temperature ratings in mind
when sizing conductors. Not doing so could result in a very expensive mistake. There are
very few cases where the high ampacities of Table 310.15(B)(17) can be utilized because
all wire has to be terminated at some point. There are also very few instances where the
90°C column of Table 310.15(B)(16) can be used for anything other than ambient
temperature adjustments or derating due to limitations of the terminals.

NEC Rules on Overcurrent

Protection for Equipment and
Conductors
How to select the correct overcurrent protection for a specific circuit based on the
requirements of Art. 240

Mike Holt | Dec 18, 2012

Mike Holt | Dec 18, 2012

Overcurrent exists when current exceeds the rating of equipment or the ampacity of a
conductor. This can be due to an overload, short circuit, or ground fault [Art. 100].
Overcurrent devices protect conductors and equipment from overcurrent. The trick is
selecting the correct overcurrent protection for a specific circuit.
Article 240 provides requirements for sufficient overcurrent protection in the correct
location. Other Articles may apply to your particular installation (see Table 240.3).

Protecting conductors

The general rule for overcurrent protection is to select an overcurrent protection device
(OCPD) that protects conductors based on their ampacities (after ampacity correction
and adjustment per 310.15). You must provide the protection where the conductors
receive their supply [240.4 and 240.21], but several exceptions to this rule exist
[240.4(A) through (G)]:

• Power loss hazard. If circuit interruption will create a hazard (e.g., fire pump circuit),
you must provide short circuit protection, but you don’t have to provide conductor
overload protection [240.4(A)].

• OCPDs rated 800A or less. If you meet the three requirements of 240.4(B), you can
use the next higher standard rating of OCPD listed in 240.6 (above the ampacity of the
ungrounded conductors being protected).

• OCPDs rated over 800A. If the OCPD exceeds 800A, the conductor ampacity (after
temperature correction, conductor bundling adjustment, or both) must have a rating of
at least that of the OCPD defined in 240.6 [240.4(C)].

• Transformer secondary conductors. You can protect the secondary conductors of a 2-

wire (single voltage) system with the primary OCPD sized per 450.3(B) as long as that
OCPD doesn’t exceed the value determined by multiplying the secondary conductor
ampacity by the secondary-to-primary transformer voltage ratio [240.4(F)].

• Specific applications. Overcurrent protection for specific equipment and conductors

must comply with Table 240.4(G) references.
Air-conditioning/refrigeration equipment and circuit conductors must be protected
against overcurrent per 440.22, and motor circuit conductors must be protected in
accordance with Art. 430 [240.4(G)].

Flexible cords and fixture wires

The NEC applies only to premises wiring, not to the supply cords of listed appliances or
luminaires or extension cords. For flexible cords and fixture wires not part of an
appliance or luminaire assembly or listed extension cord:

• Protect flexible cord with an OCPD sized for its ampacity per Table 400.5(A)(1) or
Table 400.5(A)(2) [240.5].

• Protect fixture wires with OCPDs sized for their ampacity per Table 402.5 [240.5].

Ground fault protection

According to 240.13, service equipment and feeder circuits rated 1,000A or more
supplied from a 4-wire, 3-phase, 277/480V wye-connected system must be protected
against ground faults per 230.95 [215.10 and 230.95], but this requirement doesn’t
apply to:

1. Continuous industrial processes where a disorderly shutdown will introduce

additional or increased hazards.

2. Installations where ground fault protection of equipment already exists.

3. Fire pumps [695.6(H)].

Ungrounded conductors
A fuse or circuit breaker must be connected in series with each ungrounded conductor
[240.15]. Breakers must automatically (and manually) open all ungrounded conductors
of the circuit. However, you can use individual single-pole breakers with identified
handle ties for:

• Multiwire branch circuits that supply only line-to-neutral loads [240.15(B)(1)] (Fig.
1).

Fig.
1. Individual 1-pole breakers with identified handle ties are permitted for a multiwire
branch circuit that only supplies line-to-neutral loads.

• Branch circuits that supply single-phase, line-to-line loads (120/240V) [240.15(B)(2)].

• Branch circuits that supply 3-phase, line-to-line loads on systems not exceeding 120V
to ground [240.15(B)(3)].
Location

Install OCPDs where the branch circuit or feeder conductors receive their power
[240.21]. The exceptions to this requirement are:

1. Branch-circuit taps,  if they meet the requirements of 210.19 [240.21(A)].

2. Feeder taps, if they meet the requirements of 240.21(B)(1) through (B)(5). But you
can’t use the “next size up protection rule” of 240.4(B) [240.21(B)].

3. Transformer secondary conductors, if they meet the requirements of 240.21(C).

4. Service conductors, which are protected against overload by the service disconnect
overcurrent device per 230.91 [240.21(D)].

5. Busway taps, which you can protect per the requirements of 368.17 [240.21(E)].

6. Motor circuit taps, which you can protect per the requirements of 430.28 and 430. 53
[240.21(F)].

7. Conductors from generator terminals, which you can protect per the requirements of
445.12, if they meet the size requirements of 445.13 [240.21(G)].

8. Battery conductors, for which you install the OCPDs as close as practicable to the
battery terminals 240.21(H)].

OCPDs must be readily accessible [240.24(A)]. Install them so the center of the grip of
the operating handle, when in its highest position, isn’t more than 6 ft, 7 in. above the
floor or working platform. The four exceptions to this height requirement are:

1. Busways, as provided in 368.17(C) [240.24(A)(1)].

2. Supplementary OCPDs [240.24(A)(2)].

3. OCPDs described in 225.40 and 230.92 [240.24(A)(3)].

4. OCPDs located next to equipment, if accessible by portable means [240.24(A)(4)].

OCPDs must not be:

•  Exposed to physical damage [240.24(C)].

• Located near easily ignitable material [240.24(D)].

• Located in the bathrooms of dwelling units, dormitories, or guest rooms/guest suites

of hotels or motels [240.24(E)].

•  Located over stairway steps [240.24(F)].

Enclosures

In damp or wet locations, enclosures containing OCPDs must prevent moisture or water
from entering (or accumulating within) the enclosure. When installing a surface-
mounted enclosure in a wet location, leave at least ¼ in. of air space between it and the
mounting surface [240.32].

Unless impractical, mount the OCPD enclosure in a vertical position [240.33]. You can
mount it horizontally if the OCPD meets the requirements of 240.81 (Fig. 2). Section
240.81 specifies that where circuit breaker handles are operated vertically, the UP
position of the handle must be in the ON position. So an enclosure that contains one row
of circuit breakers can be mounted horizontally, as long as the circuit breakers are
installed so that UP is ON. However, an enclosure that contains a panelboard with
multiple circuit breakers on opposite sides of each other must be mounted vertically.
 Fig.
2. Enclosures for overcurrent devices must be mounted vertically, unless impractical.

Plug fuses

Plug fuses of 15A or lower rating are identified by a hexagonal configuration of the
window, cap, or other prominent part. You can use plug fuses only when:

1. The circuit voltage doesn’t exceed 125V between conductors [240.50(A)(1)].

2. The circuits are supplied by a system with a line-to-neutral voltage not exceeding
150V [240.50(A)(2)].

Edison-base fuses are classified to operate at not more than 125V and have an ampere
rating of not more than 30A [240.51(A)]. You can use them only for replacement in an
existing installation where there’s no evidence of tampering or overfusing [240.51(B)].
You can install Edison-base fuseholders only if you install an adapter that lets them
accept Type S fuses [240.52].
Type S fuses operate at not more than 125V and have ampere ratings of 15A, 20A, and
30A [240.53(A)].

Cartridge fuses

The two basic designs of cartridge fuses are the ferrule type (maximum rating of 60A)
and the knife-blade type (rated over 60A). The fuse length and diameter varies with the
voltage and current rating.

You can use cartridge fuses and fuseholders of the 300V type only for circuits not
exceeding 300V [240.60(A)]:

• Between conductors.

• From any ungrounded conductor to the neutral point.

Circuit breakers

Circuit breakers must be capable of being opened and closed by hand. Non-manual
means of operating a circuit breaker, such as electrical shunt trip or pneumatic
operation, are permitted if the circuit breaker can also be manually operated [240.80].

Circuit breakers have an interrupting rating of 5,000A unless marked otherwise. Be sure
the circuit breaker has an interrupting rating sufficient for the short circuit current
available at the line terminals of the equipment. If the interrupting current rating isn’t
adequate, a line-to-line or ground fault can destroy equipment or result in serious injury
or death. See 110.9 for more details (Fig. 3).
 Fig.
3. Overcurrent devices must have an interrupting rating not less than nominal circuit
voltage and the current that’s available at the line terminals of the equipment (110.9).

Circuit breakers used to switch 120V or 277V fluorescent lighting circuits must be listed
and marked SWD or HID. Circuit breakers used to switch high-intensity discharge
lighting circuits must be listed and marked HID [240.83(D)].

If a circuit breaker has a straight voltage rating, such as 240V, you can use it on a circuit
where the nominal voltage between any two conductors (line-to-neutral or line-to-line)
doesn’t exceed that rating [240.85].

If a circuit breaker has a slash rating, such as 120/240V or 277/480V, you can use it on
a solidly grounded system where the nominal voltage of any one conductor to ground
doesn’t exceed the lower of the two values, and the nominal voltage between any two
conductors doesn’t exceed the higher value [240.85].
Don’t use a 120/240V slash circuit breaker on the high leg of a solidly grounded 4-wire,
3-phase, 120/240V delta-connected system. The 208V of the high leg exceeds the 120V
line-to-ground voltage rating of the breaker (Fig. 4).

Fig.
4. Circuit breakers with a 120V/240V slash rating can be used elsewhere where the
line-to-neutral voltage doesn’t exceed 120V, and the line-to-line voltage doesn’t exceed
240V.

Eye on the prize

The requirements of Art. 240 are pretty straightforward. Overcurrent protection must
be provided for every conductor based on its ampacity from 310.15 at the point where it
receives its supply, unless it fits one of the situations we have discussed [240.4].

An OCPD must be capable of opening a circuit when an overcurrent situation occurs,

and must also have an interrupting rating sufficient to avoid damage in fault conditions
[110.9]. Fulfilling these requirements is the central goal of Art. 240.
Sizing Conductors, Part XX
Share
By Charles R. Miller
 
 Published In January 2013

Table 310.15(B)(16) (formerly Table 310.16) in the National Electrical Code (NEC)
provides allowable ampacities for insulated conductors rated up to and including 2,000
volts (V). The ampacities in this table are based on no more than three current-carrying
conductors in a raceway, cable or earth (directly buried). The ampacities are also based
on an ambient temperature of 30°C.

When there are more than three current-carrying conductors and/or the ambient
temperature is other than 30°C, the table ampacities must be adjusted and/or corrected.
This is often referred to as derating. Factors, such as ambient temperature and the
number of current-carrying conductors, must be considered when sizing conductors.
Other factors, such as the temperature ratings of the terminations, continuous loads and
overcurrent protective devices, must also be considered. Therefore, when sizing
conductors, more is involved than just looking in Table 310.15(B)(16) and selecting a
conductor based on the ampacity shown.

Last month’s column concluded by covering overcurrent devices rated over 800
amperes (A). This month, the discussion continues with requirements pertaining to
overcurrent protection.

In accordance with 240.4, conductors (other than flexible cords, flexible cables and
fixture wires) shall be protected against overcurrent in accordance with their ampacities
specified in 310.15, unless otherwise permitted or required in 240.4(A) through (G). The
rules in 240.4(A) through (G) are alternatives. One alternative provision is for
overcurrent devices rated 800A or less. In accordance with 240.4(B), the next higher
standard overcurrent device rating (above the ampacity of the conductors being
protected) shall be permitted to be used, provided all of the conditions in 240.4(B)(1)
through (3) are met. This rule, in 240.4(B), is often referred to as the round-up rule.
Where the overcurrent device is rated over 800A, the ampacity of the conductors it
protects shall be equal to or greater than the rating of the overcurrent device defined in
240.6 [240.4(C)]. A new provision in Part VIII of Article 240 pertains to the protection of
conductors and includes a rule for overcurrent devices rated over 800A. Because this
new provision is in Part VIII, it only pertains to supervised industrial installations. This
part covers overcurrent protection for those portions of supervised industrial installations
operating at voltages of not more than 600V, nominal. Before covering this new
provision, it is important to understand the term “supervised industrial installation.” A
supervised industrial installation is only referenced in Article 240, and since it is only
used in this one article, the definition is in Article 240 (240.2) instead of Article 100. For
the purposes of Part VIII of Article 240, the industrial portions of a facility apply where all
three of the following conditions are met: 1) conditions of maintenance and engineering
supervision ensure that only qualified people monitor and service the system; 2) the
premises wiring system has 2,500 kilovolt-amperes (kVA) or greater of load used in
industrial process(es), manufacturing activities, or both, as calculated in accordance
with Article 220; and 3) the premises has at least one service or feeder that is more than
150 volts-to-ground and more than 300V phase-to-phase. This definition excludes
installations in buildings used by the industrial facility for offices, warehouses, garages,
machine shops and recreational facilities that are not an integral part of the industrial
plant, substation or control center (see Figure 1).

The new provision pertaining to the protection of conductors in supervised industrial

installations was added to the 2011 NEC. In accordance with 240.91, conductors shall
be protected in accordance with 240.91(A) or (B). Section 240.91(A) states that
conductors shall be protected in accordance with 240.4. For example, what size XHHW
copper conductors are required to supply a 1,200A, three-phase, 4-wire, 208V feeder
under the following conditions? The feeder conductors will be paralleled, and there will
be three sets of conductors in parallel. The load will be 1,120A, noncontinuous. The
neutral conductor carries only the unbalanced load from the other conductors and,
therefore, will not be required to be counted as a current-carrying conductor. There also
will be an equipment grounding conductor in this raceway. The feeder will be installed
indoors in a dry location. The voltage drop will not exceed the NEC recommendation. All
of the terminations will be rated 75°C. The maximum ambient temperature will be 30°C.
This feeder will be installed in a supervised industrial installation. Find the minimum size
conductors in accordance with the provision in 240.91(A).

Because there are only three current-carrying conductors and the ambient temperature
will not be above 30°C, it is not necessary to apply correction and adjustment factors.
Although the XHHW conductors are rated 90°C, the allowable ampacity shall not
exceed the 75°C column because of the termination provision in 110.14(C)(1)(b).
Section 240.91(A) states that conductors shall be protected in accordance with 240.4.
Section 240.4(C) states that, where the overcurrent device is rated over 800A, the
ampacity of the conductors it protects shall be equal to or greater than the rating of the
overcurrent device defined in 240.6. Since the overcurrent device will be 1,200A, the
total combined ampacity of the conductors must be at least 1,200A. Because there will
be three sets of conductors in parallel, the minimum ampacity per conductor must be at
least 400A (1,200 ÷ 3 = 400). The ampacity of a 600 kcmil conductor, from the 75°C
column of Table 310.15(B)(16), is 420A. Three sets of conductors in parallel have an
ampacity of 1,260A (420 × 3 = 1,260). Since the ampacity of the paralleled conductors
is at least the rating of the 1,200A overcurrent device at the feeder, this installation is
permitted (see Figure 2).

Section 240.91(B) covers devices rated over 800A in supervised industrial installations.
Where the overcurrent device is rated over 800A, the ampacity of the conductors it
protects shall be equal to or greater than 95 percent of the rating of the overcurrent
device specified in 240.6 in accordance with the two stipulations in 240.91(B)(1) and (2).
The first stipulation states that the conductors must be protected within recognized time
versus current limits for short-circuit currents. The second stipulation states that all
equipment in which the conductors terminate must be listed and marked for the
application. For example, what size XHHW copper conductors are required to supply a
1,200A, three-phase, 4-wire, 208V feeder under the following conditions? The feeder
conductors will be paralleled, and there will be three sets of conductors in parallel. The
load will be 1,120A, noncontinuous. The neutral conductor carries only the unbalanced
load from the other conductors and will not be required to be counted as a current-
carrying conductor. There also will be an equipment grounding conductor in this
raceway. The feeder will be installed indoors in a dry location. The voltage drop will not
exceed the NEC recommendation. All of the terminations will be rated 75°C. The
maximum ambient temperature will be 30°C. This feeder will be installed in a supervised
industrial installation. The conductors will be protected within recognized time versus
current limits for short-circuit currents. All equipment in which the conductors terminate
will be listed and marked for the application. Find the minimum size conductors in
accordance with the provision in 240.91(B).

Since there are only three current-carrying conductors and the ambient temperature will
not be above 30°C, it is not necessary to apply correction and adjustment factors.
Although the XHHW conductors are rated 90°C, the allowable ampacity shall not
exceed the 75°C column because of the termination provision in 110.14(C)(1)(b). Since
this installation meets the two stipulations in 240.91(B)(1) and (2), the ampacity of the
conductors can be equal to or greater than 95 percent of the overcurrent device rating.
To find the 95 percent of the overcurrent device, multiply the 1,200A overcurrent device
by 95 percent. The total combined conductor ampacity must be at least 1,140A (1,200 ×
95% = 1,140). Since there will be three conductor sets in parallel, the minimum
ampacity per conductor must be at least 380A (1,140 ÷ 3 = 380). The ampacity of a 500
kcmil conductor, from the 75°C column of Table 310.15(B)(16), is 380A. Three sets of
conductors in parallel have an ampacity of 1,140A (380 × 3 = 1,140). Since the
paralleled conductors ampacity is at least 95 percent of the 1,200A overcurrent device
rating at the feeder, this installation is permitted (see Figure 3).