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How to wire devices, and how electric devices work/pdf
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Basic
house wiring Resource How to wire devices, and how electric devices work/pdf |
| Safety | ||
 MultimeterTest for breaks in wire/ Test for voltageMost appliance require 80% rated voltage to function correctly Buy Multimeters at Amazon Electric testers at Amazon 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: What causes electrocution |
 Non-contact voltage testerTest for power without touching connectorsNEVER assume power is OFF Buy: Non-contact voltage tester Amazon Electric testers at Amazon Resource: How to test electric power is off |
| Buy Basic extremely detailed electric book at Amazon  Or learn about basic household electricity... use and search my site/ Resource All electric pages |
 Resources See inside main breaker What causes electrocution Difference between single-phase and 3-phase |
 Resource Why you need ground wire |
 Use solid copper wire not stranded wire Fire inside timer caused by stranded wire Keep enclosure door closed at all times Buy: soldering guns Resource Timer caught fire |
 Weatherproof lever switch on outdoor lights Safely operate outdoor toggle switch Replaces outdoor cover Install over top of ordinary switch Works with single-pole, double-pole, 3PST, 3-way, 4-way switches etc Use weatherproof box for outdoor Can be used indoor or outdoor Buy: Single-gang lever switch Outdoor lever switches at Amazon |
 GFCI must be installed in Bathroom, kitches and outdoor outlets Resource: How to wire GFCI |
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Single-phase
circuit breaker box found in residential installation
-Electricity arrives in the breaker box after passing through the meter box, and meter. -The breaker box has 2 Hot busbars and 1 Neutral busbar. Each Hot busbar carries 120 volt electricity that is out of phase... like the pedals on a bike, each phase in either rising or falling but always opposite the other pedal. -When double breaker is installed over two 120 volt out-of-phase busbars, there is 240 volt potential across the 2 Hot wires. -When a single-pole breaker is installed over a busbar, there is 120 volt potential across the Hot wire and the Neutral. -Each 120 volt circuit requires a How and Neutral wire. Each 240 volt circuit requires 2 out-of-phase Hot wires but does not require a Neutral. -All 120 volt and 240 volt circuits require ground wire. Resources: Generator to power pole Power pole to residential breaker box Power pole to commercial breaker box How to wire commercial 3-phase |
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Typical 120 volt circuit -Illustration shows typical 120 volt single-phase circuit found in homes and business, passing through walls and ceilings to reach each box. Maximum 12 boxes per circuit. By code, a box cannot have Hot wire supplied from another breaker. Single phase means 2 wires are needed to complete each circuit. Contrast single-phase with commercial 3 phase where 3 wires are needed to complete each circuit. Resources: Three phase electric Difference: single-phase and 3-phase |
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Typical
120
volt circuit -Illustration shows wiring for switches and outlets, including 3-way switches, in a typical 120 volt single-phase circuit with max 12 boxes. -The Neutral connects to each outlet and light, but does not connect to switch, unless it is a combination device with outlet or pilot light. Switches turn the Hot wire on and off. It is against code to turn off the Neutral instead of Hot. The Hot wire is connected to each switch and each outlet, and runs to each light. Ground wire runs continuously and connects to all devices and metal boxes in the circuit. Plastic boxes contain ground wire but ground wire does not need to be bonded to the box. Resources: Three phase electric |
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120 and 240 volt circuits, plus
dedicated circuits -Basic household wiring supplies Hot and Neutral to 120 volt circuits that serve lights, plugs and appliances. -Some appliances, such as microwave and gas water heaters with flue damper or power vent, are required to have dedicated breaker where only 1 item is served by the circuit. -Microwaves are on dedicated circuit because they draw 12-15 amps. -The purpose putting gas water heater on dedicated circuit is to prevent surges and anomalies, caused by other appliances or motors, from affecting operation of gas control valve. -All 240 volt appliances, such as water heater, subpanel, clothes dryer, oven, HVAC etc have two Hot wires and are required to have dedicated double-pole breaker. Buy: Emerson microwaves Resources: How to wire subpanel How to wire Tankless water heater Figure volts amps watts |
 Larger imageDedicated circuit Microwave oven must be on a dedicated circuit One breaker supplies power to outlet where microwave plugs in. This is required by code because microwave pulls so many amps. Other 120 volt circuit that might require dedicated circuit include window air conditioer, baseboard heater, bathroom heater, whole house vent fan. All 240 volt appliances are on dedicated circuit. The home air conditioner, clothes dryer, water well pump, subpanels, arc welder, water heater are each on a separate circuit. Other appliances might include 240 volt window air conditioner. |
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120 volt controls 240 volt water
heater 240 volt circuits can be controlled by 120V using a contactor. This lets you install timer or home automation device to any 240 volt circuit. Resources: How to wire Zwave contactor Project step-by-step How to replace circuit breaker Choose correct breaker and wire size How to add subpanel Override air conditioner with timer |
| Wire size | ||
| 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 /  Buy: 10-2 gauge/ 30 amp 10-3/ 30 amp Southwire electric tools |
Yellow
12 gauge 20 amp Yellow/ #12 gauge wire for 20 amp with ground Buy: 12-2 gauge/ 20 amp 12-3/ 20 amp NMB is house wiring UF is underground Rolls of stranded wire |
White
14 gauge 15 amp White/ #14 gauge wire for 15 amp with ground Buy: 14-2 gauge/ 15 amp 14-3/ 15 amp NMB is house wiring UF is underground |
 Buy: Armored cable |
 Southwire armored cable cutter Buy: Rolls of stranded wire |
Stranded wire  Buy: Rolls of stranded wire |
50-60
amp breaker use 6 gauge /  Buy: 6-2 wire Southwire electric tools NMB is house wiring UF is underground |
40-50
amp breaker use 8 gauge / Buy: 8-2 wire Southwire electric tools NMB is house wiring UF is underground |
  Copper ground wire Use same size as other wire in circuit Buy: 12 gauge copper ground wire Ground wire Green ground wire Ground pigtails Ground rods/ ground clamps at Amazon |
 Buy End cutting nippers at Amazon |
  When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistances on wire and creates weak point. Buy tools: Wire strippers at Amazon Linesman pliers Utility knife at Amazon |
 Buy: Multimeter Electrical testers |
 Household NM-B Wires are color-coded so inspectors/ electricians can easily identify which wire is used during construction |
Match wire size and breaker amp
rating If your home was wired by professional electrician who pulled permits, then circuit breaker and wire size will match. If manufactured home or travel trailer has not been altered by homeowner then breaker and wire size will match. If breaker is oversized for wire... fire danger Breaker can let too much electricity travel through the wire. Wire can overheat and cause fire. Call electrician if you suspect wiring is not correct, Absolute electrocution danger when removing cover off main panel. More information below. Main breaker terminals are still Hot when main breaker is turned off. Buy: Southwire at Amazon Resource: How to replace circuit breaker |
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Match breaker to voltage that
shows on appliance label 3-phase breakers are used for commercial service panels Resource: How to replace circuit breaker 3-phase wiring |
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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 DU-F Resources: Larger image with wire types, temperature, long length Maximum wattage for household NM-B and DU-F wires Wire diameter, weight, resistance |
Outlets
Volt and amp rating for switches
and
outlets is printed on the device:It is against code to connect 20 amp switch to 15 amp breaker (white 14 gauge wire) ,,, but ok to connect 15 amp switch to 20 amp breaker (yellow 12 gauge wire) Do NOT use 15 amp switch for 20 or 30 amp load. Residential switches and outlets are rated for 15, 20 and 30 amp. Single-pole switches have 2 screws and ground screw. 3- way has 3 screws and ground screw. 4-way has 4 screws and ground screw. 4 pole switches have 4 screws but can be differentiated from 4-way by 120-277V rating on 4-pole, and 120V rating on 4-way. | |
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'Old school' wiring works
correctly, but is no longer code because white wire carries power. Single pole - No Neutral Power at light fixture in ceiling All wiring must be inside a box with cover How to wire switches with no neutral wire Power enters at light fixture There are no white wires covered with wire nut and pushed to back of box. Wire colors can vary |
 | Correct wiring: every switch box has Neutral Single pole - Neutral in box How to wire switch with neutral wires present inside switch box Single-pole is when 1 switch control light(s) single-pole switch has 2 dark screws or 2 brass screws, and 1 ground screw Neutral wires are never connected to switch. Location of neutral wire affects switch wiring, because wire color can change If neutrals are present inside box, then they will be the white wires that are twisted together, covered with wire nut and pushed to back of box. Resources: Steps for replacing typical switch How to troubleshoot loose wire, ground fault, or short |
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pole - Neutral - in junction box Any box can be a junction box... with wires that go to other boxes How to wire switch inside junction box, with neutral wires Neutral is never connected to switch. Neutral wire is never connected to switch Outlet boxes always have neutral wire Switch boxes and ceiling boxes can have neutral, or they can be without neutral wire. Resource: How to wire switches |
| Outlets Volt and amp rating for switches
and
outlets is printed on the device:
It is against code to connect 20 amp outlet to 15 amp breaker (white 14 gauge wire) ,,, but ok to connect 15 amp outlet to 20 amp breaker (yellow 12 gauge wire) Residential outlets are rated for 15 and 20 amp, with both 120V and 240V ratings. How electric devices work .pdf Residential 30-50 amp outlets are larger, and used for dryers and range etc. How to wire 240V outlets |
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Outlets
are wired in parallel Electrical switches, timers, outlets, lights etc are never wired in series. Wiring in series will not work. Wiring must be in parallel as illustrated on this page. Wiring in series causes voltage drop across the line. Parallel wiring ensures that voltage remains the same across entire circuit. Notice color code on screws. Black Hot connects to Brass screw (often black color since modern screws are frequently made of steel instead of brass). Neutral universally connects to silver screw. Both Neutral screws are bonded together so 1 connection point is all that's needed. Brass screws are also bonded together, but often they are connected with a breaker-away fin that can be removed to accomplish various wiring options not shown on this page. Outlet shown is for 120 volt ONLY. DO not use two-vertical-slot outlet for 240 volt. Outlets for 240 volt have different blade configuration. How to wire 240 volt straight blade outlet The Green Ground screw is always on the Neutral side of outlet. Outlets can be rotated either way, with Neutral or Hot on left or right. This illustration shows Hot right, Neutral left. Illustration above shows the same. |
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120
volt outlets are different than 240 volt outlets 15 amp are different than 20 amp. Select correct design for voltage and amperage. DO NOT connect wrong outlet to voltage, or risk burning out electrical load. For example, plugging 120 volt drill into 240 volt plug: the drill will run very fast for a moment or two and then smoke comes out and drill motor is damaged beyond repair. Connecting electronic timer to wrong voltage will destroy timer. Resources: How to wire 240 volt straight blade outlet Figure volts amps watts Color code for wire/ breaker size |
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Single-phase 120-240 volt
twist-lock outlet or connector is
marked X-Y-W-G or X-Y-G 120V and 240V requires two wires to complete circuit, and ground wire for safety. 120V requires 1 hot and 1 neutral. 240V requires 2 hots. Neutral is not needed for 240volt electric circuit, but is sometimes included on electrical device, depending on end-user application. Resources: See inside main box Figure volts amps watts Select correct wire and breaker Electrical formulas Z is used for 3-phase and not shown here. Commercial 3-phase outlet is marked X-Y-Z-G or X-Y-Z-W-G Resource: How to wire 3-phase |
| Other wiring resources | ||
| How to wire surge protection How to wire subpanel How to wire 240 volt outlets How to wire GFCI and AFCI How to wire Combo switches How to wire Tankless water heater How to wire under counter water heater |
-Basis Safety Grounding Surge |
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 Surge Protection is a consumable product that absorbs irregular voltage and protects circuits from damage. Resources: How to wire surge protection |
 Subpanels are used to expand electric service by adding more breaker spaces Resources: How to wire subpanel |
 240 volt outlets are used for window air conditioner, RV hook-ups, electric car, dryer, range welder etc Resources: How to wire 240 volt outlets How to wire twist lock devices |
 GFCI breakers and outlets trips faster than ordinary circuit breaker to protect from shock caused by short circuit. AFCI does the same plus trips when a spark is detected. Resources: How to wire GFCI and AFCI |
 Under counter water heaters are used to provide hot water to smaller consumption areas or to supplement or replace main water heater. Resources: How to wire under counter water heater |
 Electric Tankless water heaters are used as main water heater, or as supplement to supply one area. Resources: How to wire Tankless water heater |
 Switch-outlet combos require a Neutral wire and are often used to replace ordinary outlet or switch. Resources: How to wire Combo switches How to replace outlet with combo switch |
 Pilot light switches and outlets are used to indicate when a circuit is ON or when a device has power. Resources: How to wire pilot light switch |
 Switches are connected to Hot wires only. There are 4 basic types of switches: single-pole, 3-way, 4-way, and double-pole, with varieties and speciality switches Resources: How to wire switches How to add a switch How to add a 3-way switch How to wire safety switches How to wire occupancy switch How to wire transfer switch How to wire door switch Control motor with two switches |
| How
to find ground fault in household electric circuit A ground fault is when Hot electricity reaches the ground wire or the earth, causing breaker or GFCI to trip. Symptoms include tripped GFCI that will not reset. In this case, the GFCI device might be bad. But if the GFCI is recording a fault, then troubleshooting is required to find the loose wire, bad connection, defective electrical device, melted motor winding etc. The GFCI will trip with the slightest fault current, and reacts much more quickly that circuit breaker. The GFCI reacts to a difference in current between wires, while a circuit breaker reacts to heat build-up on the Hot wire. As a consequence, circuit breakers are slow acting, and often will not trip with a slight trickle of power to ground. If the circuit is protected by AFCI instead of GFCI, then the circuit has additional layer of protection. AFCI will trip if an 'arc' is detected. The arc does not have to reach ground wire, it can merely be a loose Hot or Neutral located on a switch screw, outlet, fan motor etc. Resources How to wire GFCI and AFCI devices Difference between surge protector and ground If circuit does not have GFCI or AFCI, then the short circuit must reach the ground wire and go to earth before the breaker will trip. This emphasizes the need for proper ground wire. Breakers trip for other reasons, such as bad breaker or undersized wire for the load. The breaker trips when heat on the Hot wire exceeds breaker rating. What happens is the fault current pushes electrons down the ground wire out to the ground rod and into earth. The difference in electrical potential between charged electrons on the wire and electrons in the earth creates a strong attraction. Electrons pour down the ground wire uncontrollably trying to equalize the difference in charge between wire and earth. The number of electrons quickly exceed the rating of the wire, the wire gets hot, and breaker responds to the heat by tripping. Understanding the wires There are a maximum 12 boxes per circuit. Dedicated circuits for 240 volt appliances, and 120 volt microwaves, have 1 connection and not 12. How the wire is routed in the circuit. The 14-2 or 12-2 cable leaves breaker box and travels to the first junction box. For example a ceiling box in the nearest room is normally the first junction box. From the ceiling junction box, the cable splits off, and travels to each of the other boxes in the circuit. Any box can be a junction box where the circuit splits and carries power to another box. So a junction box can have several cables. For example, if the first junction box is bedroom ceiling box, there will be cables that travel to other boxes, and one cable might travel to next bedroom ceiling box. And so the next bedroom also has a ceiling junction box. But each box in the circuit will have only 1 cable that connects back to breaker box. When the cable arrives inside a duplex outlet box for example, another wire will leave the outlet box and travel to the next outlet box, and then travel to next outlet box or next switch box, until the last box is reached. So each box will have 1 or more cables, and the last box will have just 1 cable. However, each box has only 1 hot wire, and 1 neutral, and 1 ground that connect back to breaker box. Finding the fault First step is to isolate exactly what boxes are on the circuit. 1) Unplug all lamps, clocks, appliances, cords, clocks etc on the affected circuit. Try to reset the breaker or GFCI. If power is restored, then one of the plugged-in devices is suspect. Wait for a while to see if power continues uninterruped. Reconnect each device one by one to eliminate the good ones. If a lamp is causing the problem, then plug a good lamp into same outlet and see if problem comes back. If problem resumes with good lamp is plugged in, then turn off power and inspect wiring on outlet, and or replace outlet. Quick connection points on back of outlet fail frequently with cheap electrical devices. 2) If problem does not appear to be a plugged-in device, the switches are next suspect. Turn off all ceiling fans, lights, and switches. See if GFCI or breaker resets. If power resumes, then turn each switch back on one by one. If ceiling fan causes problem, remove, inspect, replace switch and see if problem is solved before replacing ceiling fan. If problem is inside the wiring somewhere: 3) Select one of the outlet boxes with more than one cable. Identify which cable has the Hot and Neutral. Disconnect the other cable so boxes farther from breaker are disconnected from the circuit. Turn power ON, and see if fault is still present. If fault is still present, then choose another live box that has two or more cables that is closer to breaker box, and repeat test. Process of elimination will narrow the search. Sometimes it is easier to replace all the switches, outlets and wire connectors in a room, but that is no guarantee the problem will be solved. Other causes can be rodent damage to wire, nail in wires, cable staple in wire, or some other wire damage. Resources Troubleshoot-household-electricity.html |
| Install wiring | |
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Keep wires in center of
2x4s and out of way from any nails. When remodeling, never assume location of existing wires. Use a stud finder to see inside the wall, or cut out small piece of sheetrock to view conditions before nailing. If wire has nail damage, the full length of wire must be replaced from box to box. Concealing a box inside wall is not code. |
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Switch
boxes are 50" from
floor Outlet boxes are 16" from floor |
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Run
wire down center of
2x4 to avoid nails Apply cable staples to secure wire to 2x4 Set switch or outlet box out from 2x4 to match thickness or drywall Nail staple down snug against wire. Make sure the staple does not cut into the wire. The wire should not be able to move after staple is applied. Staple is not nailed down hard... just snug. Keep wire in middle of 2x4 wall. Staple wire every 3 feet or so. |
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Protect
electric wires
from nails Apply metal plates over places where wire passes through 2x4 Drill hole through middle of 2x4 |
| Wire connections | |
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 How to test for Hot and Neutral wire: Turn power off Separate all wires for testing except ground wires. Turn power on. Tape tester leads to wood sticks for safety. Keep hands away from power. Test each wire to bare ground wire. Tester lights up on Hot wire. Hot wire should be black (except 3-way switches) Test Hot wire to all other wires except ground Tester lights up on Neutral wire. Buy: Voltage neon testers at Amazon Electric testers at Amazon |
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Outlet
polarity on outlets Hot and Neutral must be correct on outlet Hot wire connects to brass-colored screw Neutral wire connects to silver-colored screw Ground wire connects to green screw Resources: How to add a switch How to add outlet |
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Use end cutting pliers
to remove staple & nails Good tool for electric work and construction  Buy: Crescent-brand end cutting nipper at Amazon End cutting nippers at Amazon |
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Stripping wire Carefully slice through coating on wire Cut down middle of cable over the ground wire Use sharp blade  Buy: Utility knife at Amazon Wire stripper Terminal crimp tool When stripping, do not score or make a cut on the copper wire surface. Cuts on copper wire can increase resistance and heat on wire. Buy: Wire strippers at Amazon Resources: Color code for wire |
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Twisting wire Use Linesman pliers Buy tools: Wire strippers at Amazon Linesman pliers Utility knife at Amazon End cutting nippers at Amazon Resources: How to twist wire |
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Wire connectors Solid copper wires do not need to be twisted together, but I recommend twisting wire to ensure strong permanent connection. If wires are twisted, then make sure the two wires are twisted very tight. To install connector, turn wire connector very tight against copper When finished, ask two questions: Does connector cover past the copper wire? Yes Is connector tight enough that it will never fall off? Yes Will the wires pull out of connector? No Answer 'yes' to first two questions, and no to last question, you have right connector, and connection is secure.  
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 Cut
stranded wire longer than solid copper, then wrap
stranded around copper before applying wire connector.Do not reuse old connectors Buy: Connector assortment at Amazon Connector assortment at Amazon Resource How to select and install twist-on wire connectors |
 maximum 2 wires under screw plate Same gauge wire under screw plate |
Push
on wire connectors Buy: Push on wire connectors at Amazon Red 3P connector (shown) for 10-14 gauge wire Resource Electric safety when wiring timer |
 Terminals Buy: Terminal kit Blue for 16-14 wire Yellow for 12-10 wire Read about terminals Resource: How to install terminals |
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| Circuit breakers and fuses | |
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Circuit breakers 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 Circuit breakers How to install subpanel Why you need ground wire Match breaker and wire size How to wire subpanel See inside breaker box How to wire safety switch How to wire whole house surge protector |
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Water heater blowing breaker Move wires to different same-size breaker and see if problem continues Resources: Water-heater-is-blowing-breaker Stress test breaker panel How to replace circuit breaker Color code for wire |
 Safety switch  fusable pull-out |
Pull-out disconnect -or-
Non-fusable Safety cut off for outdoor installation: Locate cut-off next to electric equipment ... or short reach away... within sight of appliance. Purpose to protect anyone working on electricity ... so person knows power is OFF, and power cannot accidently be turned ON. Resource How to wire safety switch Residential information: varies by state and locale Non-fusable safety switch required on outdoor installations, and high-voltage indoor applications such as 90 amp tankless electric water heater where breaker box not in plain sight of equipment. fusable vrs non-fusable: Non-fusable means there is no breaker or fuse inside the cut-off box. Non fusable is manually-operated on-off switch for safety. fusable means there is a fuse or breaker that trips when detecting high heat. Resource How to wire safety switch Buy: Pullout Disconnect at Amazon fusable pullout disconnect 2-pole 30 amp fusable safety switch/ power cut-off 2-pole 60 amp non-fusable safety switch |
 Ground wireAll phone, satellite, pool equipment, solar systems and electric panels must be grounded. Check local electric codes. What does this mean? Bonding is the connection of metal to a ground wire that is in turn connected to a ground rod driven into the earth to a depth that meets local codes for grounding. Drive ground rod 8-10 feet into soil. Bond #6-8 bare copper wire to ground rod and to solar panels and pipes on roof. Do NOT ground electric system to water pipes. Ground must be connected to ground rod. Stray current corrosion can cause pipes to deteriorate. Uncertain bond to ground because of plastic pipes. Buy: Ground rod and clamps at Amazon Bonding lugs Bond all ground wires together to help prevent surge & lightning damage. Bonding all grounds together will help prevent damage from lightning strikes beyond 100' away... Strong lightning strikes within 100 feet must be handled by lightning rod Local code requires bonding: this includes all ground rods for satellite, TV, phone, solar, electric panel, subpanels (within 100 feet) etc must be connected together and bonded to main electric panel ground rod driven into soil at correct depth to meet local code. Consult local electrician. Codes for grounding depth vary: loose rocky dry soils are less conductive than dense wet soils No system other than lightning rods will protect against direct lightning strike or strike within 100 feet. Move indoors and do not stay on roof, or move metal ladders, or touch anything made of metal when lightning is within 1 mile or can be heard or seen. Resource Why ground wire is needed |
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 Contactors/ relays |
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