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Resource: safe electric wiring
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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  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  Buy: 8-2 wire Southwire electric tools NMB is house wiring UF is underground |
 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 |
 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 |
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NM-B wire
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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 |
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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 |
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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 |
 Extension cords18 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? |
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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 |
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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 |
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Use
larger wire and breaker with longer distance Length of wire/ amp draw chart |
| Motor charts | |
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''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 |
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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 |
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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 |
 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 |
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| " 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 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 |
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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 |
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Single
phase
Horsepower / wire size / distance  Larger image |
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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 |
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Single-phase/
3-phase Amp load by Kilowatt |
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Single-phase/ 3-phase Amp load by Kilowatt/ 2 |
 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 |
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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 |
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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 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 Buy: 30 amp DPDT switch 30 amp double pole switch Resource: Use this switch to toggle water heater between 120-240 volt |
 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 |
Larger imageHousehold 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 |
 120 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 |
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What is 3-phase electric: power plant to end
user
Basic house wiring |
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Buy
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