MODULE 8 – Engineering Utilities 1
Current Carrying Capacity
Introduction
The term ampacity is generally used to specifically describe the carrying capacity of wires or
cables. It is an important electrical safety concern as exceeding the ampacity of an electrical
system may damage it, resulting in a dangerous electrical fault such as an arc flash or
electrocution hazard. Exceeding a system’s ampacity can also pose a fire risk.
The amount of heat generated by a given current depends on the resistance of the conductor the
current is flowing through. Because ampacity measures the ability of a wire or cable to dissipate
heat, the ampacity of a wire will generally increase with the diameter of the wire—the larger the
wire, the more effectively it can dissipate heat. A wire’s ampacity is limited by the ability of its
jacket and insulation to withstand the heat the wire generates.
Factors Affecting Ampacity - The ampacity of a conductor depends on:
1. its insulation temperature rating;
2. the electrical resistance of the conductor material;
3. frequency of the current, in the case of alternating current;
4. ability to dissipate heat, which depends on conductor geometry and its surroundings;
5. ambient temperature.
All common electrical conductors have some resistance to the flow of electricity. Electric current
flowing through them causes voltage drop and power dissipation, which heats conductors.
Copper or aluminum can conduct a large amount of current without damage, but long before
conductor damage, the resultant heat would typically, damage insulation.
Voltage Drop in Wire = Circuit current x Resistance of wire
Power Loss in wire = Circuit current x Voltage drop
POWER LOSS = is equal to the components resistance times the current squared. The power
loss being converted into heat, must be dissipated. A small wire diameter can safely carry more
current in proportion to its weight. The use of copper wire is most preferred.
Conductor size and rating shall have sufficient ampacity to carry load. They shall have adequate
mechanical strength and shall not be less than the rating of the branch circuit and not less than
the maximum load to be served
ALLOWABLE AMPACITIES OF INSULATED COPPER CONDUCTORS NOT MORE
THAN 3-WIRES IN A RACEWAY
SIZE Temperature Rating of Conductor
60ᴼ (140ᴼ F) 75ᴼ (167ᴼ F) 90ᴼ (194ᴼ F)
Type Types Types
2 AWG RHW SA
mm
MCM T THW RHH
THWN THHN
TW XHW XHHW
2.0 14 15 15 25
3.5 12 20 20 30
5.5 10 30 30 40
8.0 8.0 40 45 50
14 6 55 65 70
22 4 70 85 90
30 2 80 100 105
38 1 100 110 115
50 1/0 120 145 150
60 2/0 135 160 170
80 3/0 160 195 205
100 4/0 185 220 225
125 250 210 255 265
150 300 240 280 295
200 400 280 330 355
250 500 315 375 400
325 650 370 435 470
400 800 405 515 515
500 1000 445 580 580
Example:
1. A 38 AWG copper conductor with a temperature rating of 60°C has a maximum allowable
ampacity of 85 amperes.
2. The maximum allowable ampacity of the same 3 AWG copper conductor with a temperature
rating of 75°C is 100A.
3. If the temperature rating of the 3 AWG copper conductor is 90°C, the allowable ampacity is
115A (see Figure 2).
4. What size of THHN conductor for a 156 A load?
5. THW conductor in mm. sq. of lighting load having 8.9 A?
6. Sub-feeder size of an ACU @ 12 A full load current. Select THHN wire.
Wire Size and Ampere Ratings
Ampacity is the maximum current that a conductor can carry continuously under the
conditions of use without exceeding its temperature rating. Current is measured in
amperes or “amps.” You must use the correct size wire for the current (load) requirement
of the circuit to prevent the wire from overheating.
The number and type of electrical devices connected to a circuit determine the ampacity
requirement of the conductor. Usually, a general-purpose house circuit is designed for 20
amps. Lighting circuits may be designed for only 15 amps.
To calculate the load requirement for a circuit, first add up the wattage of all the electrical
devices that will be on the circuit. Then, divide the total wattage by the voltage of the
system, typically 120 or 240, and that will give you the required current or amps.
CHARACTERISTICS OF SELECTED INSULATED CONDUCTORS FOR GENERAL
WIRING
Trade Name Type Letter Operating Application Provision
Temp
Moisture and heat Resistant Rubber KHW 75ᴼ C Dry and Wet location
Thermoplastic T 60 ᴼ C Dry location
Moisture Resistant thermoplastic TW 60 ᴼ C Dry and Wet location
Thermoplastic heat resistant THHN 90 ᴼ C Dry location
Moisture and heat resistant plastic THW 75 ᴼ C Dry and Wet location
Moisture and heat resistant THWN 75 ᴼ C Dry and Wet location
thermoplastic
Moisture and heat resistant cross linked XHHW 90 ᴼ C Dry location and wet
thermosetting
Polyethylene 75 ᴼ C Wet location
Silicon Asbestos SA 90 ᴼ C Dry location
110 ᴼ C Dry location
Source: The National Electrical Code
Example:
1. What’s the conduit size of no. 12 AWG copper wire with type thhn
insulation installed in a raceway with 35 wires?
Answer: 1 ¼ inch
2. If there are 5 x 4.0 AWG wires, what’s the size of the conduit to be used?
Answer: 1 ¼ in
-------------------------------------------------------------------------------------------------------------------------------------------
End of Module…. Thank you and stay safe.
Engr. GEORGE P. ALONZO
Professional Electrical Engineer
