Problems
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For three-phase feeder circuits, do not downsize the grounded conductor or neutral.
For three-phase circuits where significant non-linear loads are anticipated, it
is recommended to install grounded or neutral conductors with at least double the
ampacity of each phase conductor.
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Examples //
The interactions between conductor sizes, load currents, and conductor lengths at various supply
voltages are shown in Table 1 below.
The combinations of various load currents from 8 to 30 amperes and supply voltages
from 120 to 480 volts are shown in the left two columns of the table. The next four columns show the
maximum circuit lengths (one-way) for four different conductor sizes to attain a 3%
voltage drop. The last four columns are maximum lengths for an allowable 1.5% voltage drop.
For example, a 12 ampere load in a 120 volt circuit on a 14 AWG conductor will exceed a
3% voltage drop (3.6 volts) if the circuit is longer than 49 feet from source to load.
If the conductor is upsized to 12 AWG the allowable distance increases significantly to 78 feet each
way (an increase of 59%). If the load is increased to an allowable maximum of 15 amps for 14
AWG conductor, the allowable length is only 39 feet, and moving to a 12 AWG conductor
would increase this to 62 feet (also an increase in length of 59%).
The 1.5% data values are given for situations when it is necessary to comply with NEC 647.4(D).
Verify the equipments actual requirements whenever possible. The much tighter 1.5% voltage drop
allowance on the right side of Table 1 cuts the allowable lengths to only 1/2 of their values at 3%
voltage drop. Conductor upsizing is often mandated for the protection of sensitive electronic
equipment. Voltage drop can be minimized if the panel or subpanel can be located as close as possible
to the point of use.
Another measure is to install sufficient circuits to avoid high current levels on any one
circuit. Where loads can be split onto separate circuits, the reduced load per circuit will enhance
quality and reliability.
Perusal of Table 1 inevitably leads to the conclusion that voltage drop is too often
ignored.
For example, the lengths of many branch circuits in 14 AWG wire exceed even the 3%
voltage drop of 39 feet, not to mention the tighter 1.5% drop of 20 feet. When this
happens, the integrity of both the wiring and of many loads is put in jeopardy.
/1,000 feet for a 3% drop (or 3.6 volts) is 78 feet. Since the conductors must carry the
current over and back, the allowable one-way distance from source to load is 39 feet.
For convenient use of the NEC tables, loads are assumed to be purely resistive, directcurrent loads. Alternating current values differ only slightly. Harmonics or inductive loads may
accentuate voltage drop, and decrease recommended circuit lengths.
Maximum Recommended Lengths of Single-Phase Branch Circuits, as a Function of Load Current, Supply Voltage, and Conductor Size, for
Both 3% and 1.5% Voltage Drops
Calculations are based on resistance values found in NEC Chapter 9, Table 8 for solid,
uncoated copper conductors. For 14 AWG, the resistance is 3.07 /1,000 feet, for 12 AWG it
is 1.93 /1,000 feet, for 10 AWG it is 1.21 /1,000 feet, and for 8 AWG (stranded) it is 0.778
/1,000 feet. Conductor temperatures higher than 75C (167F) will increase these resistances,
and vice versa.
Reference: Recommended Practices for Designing and Installing Copper Building Wire Systems
Copper Development Association Inc.