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Color-code for residential wire/ how to match wire size and circuit breaker

Resource: safe electric wiring


Use only 600 volt wire.
Lamp cord, extension cords are not rated 600 volt.
Use copper wire only. Aluminum wire is fire risk and should be avoided or installed by professional.

30 amp breaker use 10 gauge /
120-240 volt 30 amp outlet can be installed on 30 amp breaker only/ use 10 gauge wire ... cannot be connected to 15-20-40 amp breaker.

Orange/ #10 gauge wire, with ground ... 30 amp capacity. Safe maximum: 30 x 80% = 24 amps.
Buy:
10-2 gauge/ 30 amp
10-3/ 30 amp
Southwire electric tools
Yellow 12 gauge 20 amp
120 volt 20 amp outlet can be installed on 20 amp breaker, but not 15 amp breaker/ use 12 ga wire.
... cannot be connected to 30-40 amp breaker. 1

Yellow/ #12 gauge wire, with ground ... 20 amp capacity. Safe maximum 16 amps.
Buy:
12-2 gauge/ 20 amp
12-3/ 20 amp

NMB is house wiring
UF is underground
Rolls of stranded wire
HOOK UP Wires
50-60 amp breaker use 6 gauge /
240 volt 50 outlet can be installed on 50 amp breaker only
6-2 wire
Buy:
6-2 wire
Southwire electric tools
NMB is house wiring
UF is underground
40-50 amp breaker use 8 gauge /
240 volt 40 amp outlet can be installed on 40 or 50 amp breaker only
6-2 wire
Buy:
8-2 wire
Southwire electric tools
NMB is house wiring
UF is underground
multimeter
Multimeters
Voltage is tested across two separate wires. Ohms or resistance is tested across both ends of same wire. Amperage is tested along one or two points on same wire.
Buy:
Analog multimeter
Multimeters at Amazon
Klein multimeter
Electric testers at Amazon
Clampmeter for testing amp flow on line
Southwire armored cable cutter
Electrical tools must be insulated.
Always best to disconnect power, but insulation failure, lack of proper grounding, grounded neutral, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems still pose a risk to anyone working on electric power ... even when breaker is off.

Buy:
Electrician tools kits
KLEIN TOOLS
Tools kits
IRWIN tools
KNIPEX

Telephone cable knife
Low Voltage Mounting Bracket for Telephone

Protect wiring from damage
Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable.

-Code says: Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15
Buy
End cutting nippers at Amazon


Electrically insulated tools
When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistance and heat on wire and creates possible weak point.
Buy tools:
KLEIN TOOLS
Wire strippers at Amazon

Linesman pliers
Utility knife at Amazon

NM-B wire
Applies to all types of wire

Match wire size and breaker amp rating

If breaker is oversized for wire... fire danger
Breaker can let the voltage push too much amperage (current of electrons) through the matrix (atomic structure) of the wire. The natural resistance of the copper wire creates a 'friction' that overheats the wire and causes fire.

Household NM-B Wires 14 thru 10 gauge are color-coded so inspectors/ electricians can easily identify which wire is used during construction

Safe maximum of amp draw on a breaker is 80% rated value of breaker.
Look at label on each load (TV, refrigerator, box fan etc). Add up total watt load on circuit. Divide the watts by the voltage on line = amps.

Use 600 volt solid copper wire only
Do not use aluminum wire

Do not use extension cord for permanent household wiring
Extension cords are used for connectors and plugs only.
Read about extension cord code
wire size chart Circuit breaker and wire size must match
Chart on left shows that 30 amp breaker matches 10 gauge copper wire.
Do not use aluminum wire. Copper wire is safe.
All wire expands when electricity travels through wire. Aluminum wire expands more than copper wire. Expansion causes connection points to come loose resulting in fire hazard.
Special compression fittings and CO-AL rated devices must be used with aluminum wire.

Image on left shows rating for lengths up to 100' feet for household NM-B and UF-B
Resources:
Larger image with wire types, temperature, long length
Maximum wattage for household NM-B and DU-F wires
Wire diameter, weight, resistance
UF-B wire for Damp- wet locations:
For direct burial underfoot, in contact with damp soil ... or for other damp locations ... use UF-B wire ... or use plastic conduit.
UF-B wire can be difficult to strip back for wiring. Using sharp blade on utility knife, push blade into end of grey cable sheathing next to ground wire. Keep blade next to ground so it will not damage insulation on black-white wires. After cutting into sheathing 3-4," you can gently strip grey cable sheathing from around the black and white wires, being careful not to damage insulation.
All wires use same breaker chart
Buy:
Southwire at Amazon
Resources:
How to replace circuit breaker
Southwire Romex NM-B specification and usage manual
Southwire UF-B specification and usage manual
Ampacities for TW and UF insulated wires: NEC table 310-16
Vacuum cleaner cord gets hotExtension cords
18 gauge extension cord, used for table lamp etc is rated max 7 amps.
14 gauge extension cord, frequently used for power tool cord, is rated 10 amps.
Never use extension cord in place of house wiring. House wiring is rated 600 volt, extension cords are not.
Extension cords are temporary and cannot be concealed inside wall. Extension cords are made for plug ends, and have stranded wire instead of solid wire. Never put stranded wire under screw plate of switch, timer etc. or it creates fire hazard.

Cords should not be warm if they are used full-time

If you are using extension cord as full time source of electricity for pump or fan, the cord should not be warm or hot
If toaster oven cord gets warm when used, then that is normal
If you operate the appliance full time, then upgrade to larger cord
\
Buy
12 gauge extension cord

''Flexible cords and cables may not be used:
a. As a substitute for the fixed wiring of the structure;
b. Where run through holes in walls, ceilings, or floors;
c. Where run through doorways, windows, or similar openings;
d. Where attached to building surfaces; or
e. Where concealed behind building walls, ceilings, or floors."

Flexible cord splices, repair and connections:
"Flexible cords shall be used only in continuous lengths without splice or tap.  
No. 12 or larger, may be repaired if spliced so that the splice retains insulation, outer sheath properties, and usage characteristics.
Flexible cords shall be connected to devices and fittings so that strain relief is provided which will prevent pull from being directly transmitted to joints or terminal screws." In other words, the cord must be connected or held in place by a clamp or other means so it cannot be pulled loose from terminal screws.


Circuit breakers are rated 600 volt, same 600 volt rating as electrical wire and cables
Single, Double, Triple breakers
Single breakers and tandem breakers are used for 120 volt residential, and for single-phase commercial voltages like 120 and 277V.
Double breakers are used for commercial and residential voltages like 208 and 240 volt.
Triple breakers are used for 3-phase commercial service panels up to 600 volt.

Code says: Use connected/ double-pole breaker
Against code to use 2 single breakers to supply 240 volt, unless the switches are connected by a bar

If double breaker is rated for 30 amp, then BOTH sides of the breaker are each 30 amp (not 15 amp each)
Power is doubled with 240 volt vs 120 volt, amps are not halved

Resource:
How to replace circuit breaker
3-phase wiring
Are both sides of 30 amp double breaker 30 amp?
circuit breaker resources
Circuit breaker resources
Water heater is tripping breaker
How to replace circuit breaker
How to wire gfci
Can AC breaker be used for DC breaker
How to reset circuit breaker
Not enough space for circuit breakers/ use tandem
Circuit breakers
How to install subpanel
Why you need ground wire
See inside breaker box
How to wire safety switch
How to wire whole house surge protector
Figure volts amps and watts
Figure correct wire and breaker
Types of surge protection


Larger image
How to figure correct size wire and breaker
Use chart on left to select wire and breaker (for short lengths of wire)
Use the 80% rule when calculating Capacity.
wattage shown on chart shows the 80% rule.
When wires and breakers operate at 100%, they get warm.
Warm wires mean amp loss and potential fire hazard.
Warm breaker means that breaker will not last as long, and busbar can be damaged by heat (over period of time)

14 ga wire ++  rated for 120 Volts x 15 Amp = 1800 Watts x 80% = 1440 Watts safe maximum

12 ga wire ++ rated for 120 Volts x 20 Amps = 2400 Watts x 80% = 1920 Watts safe maximum

10 ga wire ++ rated for 240 Volts x 30 Amps = 7200 Watts x 80% = 5760 Watts safe maximum


Resource
Basic house wiring

Larger image
Longer distance requires larger breaker and larger wire
Look at label to find watt rating of appliance, or motor or tool
measure distance between appliance and main breaker panel
Use chart to select larger wire when needed
Volts x amps = watts
Watts divided by volts = amps
Volts squared divided by watts = ohms

Resources:
Electrical formulas/ pdf
How to figure volts amps watts
Electric terminology
Electrical formulas
Water heater formulas

Larger image with wire types, temperature, long length
Maximum wattage for household NM-B and DU-F wires
Wire diameter, weight, resistance
Use larger wire and breaker with longer distance

Length of wire/ amp draw chart


Motor  charts
motor ''For motor Loads multiply running current by 1.75-2.50 to get circuit breaker size''
Resource
: NEC rules p 13/ pdf

Always connect ground wire.

Buy:
AO smith / Century / motors at Amazon
Dayton motors at Amazon
Electric motors at Amazon

amp draw for motor
Resources:
Motors can run 10% more or 10% less than rated voltage
Magnetic motors is AO Smith, AO Smith motors are now Century
Resources
AO Smith motors with troubleshoot and wiring .pdf
AO Smith motor wiring

Motor troubleshooting/ pdf
Motor troubleshoot 2/ pdf
Timer for 2-speed motor
Repair and wire motors .pdf
Basic motor wiring illustration .jpg
Reverse motor .pdf
Hayward pool equipment error codes
Swimming pool replacement motors and identification
The motor doctor
Dayton motor guide/ pdf
Control motor with 2 switches
Wattage consumption of motor .pdf

Horsepower rating of plugs and receptacles
FLA:   Full-Load Amperes
LRA:   Locked rotor amperage

When starting a motor the currents are 6 to 8 times the normal running current.

Example. A 240 volt 1 Hp AC motor for swimming pool cannot begin rotating until it receives a brief surge of amperage that exceeds 48 amp.
Circuit breakers are not fast-acting, and allow the brief surge of amperage needed for motor starts.
KVA = (HP)(kVA/HP)

"With inductive loads like motors, the current (amperage) lags the voltage, therefore motors have a lagging power factor." The voltage provides the magnetizing power needed to start motor. This causes voltage drop.

"With capacitive loads, (such as capacitor banks that power company installs along the power lines), the current leads the voltage, therefore they have a leading power factor." This causes voltage to rise, and counterbalances the effect of motor starts on the grid.
Read  

Volts x Amps = Watts
Amps = Watts divided by Volts
FLA:   Full-Load Amperes
LRA:   Locked rotor amperage 

Calculate inrush for 3-phase motor:
Inrush is the amp consumption of a motor during start-up.

Motors are inductive. Inductive loads consume more amps when starting. Once the motor has started, the amperage drops to normal.
Inrush is an issue with large commercial motors. Residential single-phase motors have inrush, but it's generally not an issue with 1-2 hp motors.

Example calculation shows 3-phase 480volt 50 hp motor.

Each motor has a label with a locked-rotor code that is needed for the calculation.
The locked rotor code is a letter A-V, with each letter corresponding to a range of KVA per HP (horsepower).
KVA is kilo volt amps. Volt amps is watts. So KVA is a measure of watts or power ... how much power the motor delivers.
The locked rotor code is used to calculate the inrush of amperage needed for that specific motor during start up.

The example problem above shows motor with locked-rotor H, which has KVA range of 6.3-7.1 KVA per HP.
The KVA range is plugged into the formula:
P (power or KVA) = E (volts) x I (amperage) x .173
1.73 is the square root of 3, used for 3-phase calculations.
I or amperage is unknown.
I = (1.73 x 480 volts) divided by 354,500 KVA

Resources:
Locked rotor KVA nameplate rating: Calculate inrush .pdf
Difference between single-phase and 3-phase
" Current capacity must be adequate enough to maintain rated voltage at the motor terminals under all conditions. If voltage too high, contact the local utility.
If it’s too low check for overloaded circuits, loose connections or wire of the wrong gauge"
More than 3300 feet above sea level, use next higher horsepower motor.
Motor must be grounded. Test that ground is connected. Turn power off before touching motor.
Incorrect voltage at motor will cause motor to overheat. Check wire size.
Motors are hot to touch. Provide ample circulation around motor.
Motor amp chart
Motor amp chart

Single-phase and 3-phase amp draw

1/6-1/4 HP motors are typical for house ventilating and bathroom fans.
1/2-3/4 HP for household pumps, shop tools etc
1 HP for household water well, swimming pool, table saw etc
Larger image

The chart shows that 240 volt single phase 5 HP motor draws 28 amps, while the 240 volt 3-phase 5 HP draws 15.2 amps.

Lower amp draw on the 3-phase circuit means less heat per HP, higher output per amp used, higher output per KWh, and means a smaller wire and breaker can be used, offsetting the cost of the third wire.

This illustrates that 3 phase can run a motor more efficiently than single-phase, and is the reason why 3-phase is used for commercial applications.

The breaker and wire must match the load, no matter if it's a 3-pole 3-phase breaker, or 2-pole single-phase breaker.

The complexity of 3-phase, requiring 3 transformers, third wire, and need for load balancing are the reason why single-phase and not 3-phase is used for household power.
Resource: Difference 3-phase and single-phase

Horsepower / wire size / distance
Motor horsepower and wire size for 115Volt and 240V
Horsepower = watts ÷ 746
Resource:
How to wire subpanel

For example: 1-1⁄2 Hp motor at 115 volts over a distance of 150 feet, use #8 wire.
If the motor can be installed to operate on 230 volts, #12 wire should be sufficient for a 150 foot distance
Single phase
Horsepower / wire size / distance

Larger image

3-phase wire size
Larger image

Single-phase/ 3-phase Wire and Breaker size chart

Resources:
What is 3-phase
How to wire 3-phase
3-phase timer
3-phase contactor
Difference between single-phase and 3-phase


Larger image
Single-phase/ 3-phase Amp load by Kilowatt

Larger image
Single-phase/ 3-phase Amp load by Kilowatt/ 2
Water heater wire size chart
Larger image
Dual-element water heaters are 240Volt and are normally factory-wired for non-simultaneous.
This means only one element is ON at a time.
Both elements are never ON at same time.
Water heater Circuit Breaker size/
non-simultaneous

Ordinary residential water heaters are non-simultaneous. Tank label will show type of operation.
Longer distance, use larger wire and breaker
Oversizing wire and breaker will lower heat loss and improve efficiency
Cooler wires = cooler circuit breaker = longer life for breakers and main panel
Resource:
How electric water heaters work
Single-phase water heater amp draw
Larger image
Water heater  Amp draw/
non-simultaneous/ 


Ordinary residential water heaters are non-simultaneous
Same as chart above except showing actual amp draw instead of recommended breaker size
Simultaneous water heater wiring
Larger image
.pdf file
Water heater  Amp draw/
simultaneous

Residential water heater, or commercial water heater can be wired for simultaneous operation.
Some regions require commercial food sellers to have manufacturer-certified commercial-grade simultaneous water heater
Simultaneous is NOT typical for ordinary residential water heaters, except special order, or some models with 80 gallon capacity. Tank label will show type of operation.
Chart shows typical residential single-phase 120Volt, and 240Volt.
Chart also shows voltages found with commercial 3-phase service.
Water heaters can be wired for 3-phase
Resource:
How to wire water heater for simultaneous operation
How to wire 3-phase water heater

30 amp switches
Cooper 30 Amp switch
Single-pole/ 2-pole on-off switches
Buy:
30 amp 2-pole switch
30 amp industrial grade
Leviton 3033 switch
30 amp 3-way switch
30 amp Motor start switch

Heavy duty double-pole switches to turn off both hot wires in 240 volt circuit
Buy 2 pole:
30 amp motor switch
40 amp motor switch
Buy:
3-pole 40 amp switch
30 amp DPDT
Double pole double throw 30 amp switch
Buy:
30 amp DPDT switch
30 amp double pole switch
Resource:
Use this switch to toggle water heater between 120-240 volt
water heater circuit breaker

4500 watt and 5500 watt water heaters should connect to 30 amp breaker and 10 gauge wire.
Calculate safe maximum for water heater circuit
If residential water heater is connected to 20 amp breaker and 12 gauge wire, then overheating problem occurs over time.
Circuit breaker will not last as long, and damage can occur to busbar.
Resource:
See basic water heater circuit
How to replace circuit breaker
20 amp breaker is subject to 80% safe-maximum rule.
20 amp circuit breaker x .8 = 16 amps. So safe maximum for 20 amp breaker is 16 amps.
240Volt 4500 watt water heater draws 18.75 amps. And 5500 watt water heater draws 22.91 amps.
So 20 amp breaker with 12 gauge wire is rated too small for most water heaters. Over time the breaker is getting warm, and is more likely to get hot and fail.

Recommended that all water heaters be connected to 30 amp breaker and 10 gauge wire.
Safe maximum for 30 amp breaker x .8 = 24 amps.
Safe maximum for 10 gauge wire at 240volts is 5670 watts See chart
30 amp breaker and 10 gauge wire run cooler, with less heat loss and more efficiency. Circuit breaker and main box last longer with less chance for heat damage.
Resource:
Figure Volts Amps Watts for water heater

GFCI in breaker box Larger image

Household Main panel 120 volt and 240 volt

This is called single-phase electric power. Phasing is determined by the power company.

- Each 120 volt circuit can include up to 12 outlets, and supply power to lights inside a room.
- Generally each 120 volt circuit sends power to one area of home. This is because the wire leaves breaker box and goes to first junction box inside a room. From the junction box, the wire splits off and goes to each individual box, jumping from box to box until the final box is reached. So each box will have 1 black hot wire, 1 white neutral wire, and 1 ground wire that connect back to main breaker box.
- Some circuit breakers are dedicated to 1 specific appliance. For example the kitchen microwave is usually wired to 1 circuit breaker and no other outlets or lights are connected to that breaker. This is because microwave draws so much amperage. to 1 specific appliance. For example the kitchen microwave is usually wired to 1 circuit breaker and no other outlets or lights are connected to that breaker. This is because microwave draws so much amperage. That is called dedicated circuit, and dedicated breaker.

- Each 240 volt circuit is dedicated to one appliance. For example electric water heater is connected to 1 240 volt breaker. The electric dryer is connected to another 240 volt breaker. The heat/AC is connected to another 240 volt circuit breaker, and so on.
Code
"-Metal boxes SHALL BE grounded with a separate machine threaded ground screw. NEC sec. 370-4 and 250-114a
-All openings in boxes (enclosures) SHALL BE adequately closed. NEC sec. 370-17a
-All cable jackets SHALL extend at least 1/4 inch into the box. NEC sec. 370-17c
-All cable SHALL BE secured to the box, except for single gang non-metallic boxes, if stapled within 8 inches of the box. NEC sec. 370-17c
-Unused openings in boxes SHALL BE effectively closed. NEC sec. 370-18"
Resources:
See inside main breaker box
Basic house wiring
Safe electric wiring
How to replace circuit breaker
How to install subpanel
Figure volts amps watts for electric water heater
How to wire GFCI
How to wire Arc fault breaker

Multimeter
Test for breaks in wire/ Test for voltage
Most appliance require 80% rated voltage to function correctly
Buy
Analog multimeter
Multimeters at Amazon
Klein multimeter
Electric testers at Amazon
Clampmeter for testing amp flow on line
Resource:
How to test and replace element
How to test thermocouple
Element tests for 120 volts
How to test wire

Safety when testing wires:
Never touch wet or previously flooded appliance.
Never stand on wet surface when working on electric.
Never stand on bare soil, put down dry boards.
Tape tester leads to wood sticks to keep hands away from power.
Use non-contact voltage tester before touching wires.
Never touch or lean into any made of metal.
Remove metal objects from pockets.
Do not use oxygen or fuel accelerants in same room as electrical repairs

Resource:
Basic house wiring
GFCI receptacle120 volt 15 amp devices including GFCI, timers, switches, plugs, wifi controls etc can be installed on 15 or 20 amp breaker.

120 volt GFCI, outlet, receptacle that is rated 20 amp can be installed on 20 amp breaker only, but NOT on 15 amp breaker.  
Buy
15 amp GFCI
20 amp GFCI


Non-contact voltage tester
Test for power without touching connectors
NEVER assume power is OFF
Buy
Basic electric book
Home plumbing/ electrical codes
Buy:
Non-contact voltage tester Amazon
Electric testers at Amazon
Resource:
How to test electric power is off
Electricity leaves power plant What is 3-phase electric: power plant to end user

Basic house wiring





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