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Color-code for residential wire/ how to match wire size and circuit breaker
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Wire size
for motor Color-code for residential wire/ how to match wire size and circuit breaker |
| 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 |
White
14 gauge 15 amp 120 volt 15 amp outlet, AFCI, GFCI, timer, switch etc can be installed on 15 or 20 amp breaker. Never connect 15 gauge wire to 20-30-40 amp breaker.  White/ #14 gauge wire, with ground ... 15 amp capacity. Safe maximum 12 amps. Buy: 14-2 gauge/ 15 amp 14-3/ 15 amp NMB is house wiring UF is underground |
| 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 |
  Copper ground wire. Every device, load, metal enclosure etc must be grounded. Ground wire must be continuous throughout installation, never switched on-off, never used as a Neutral wire. Generally ... 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 |
 Non metallic flexible cables must carry ground wire, but do not have hazard of short circuit causing injury from shock. Armored steel cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure. All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes. Movement, damage and deterioration are major cause of electrical failure. Buy: Non-metallic flexible conduit Power whip Armored cable Southwire armored cable cutter Pull boxes |
 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 |
 600 volt 12 ga Stranded wire ot THHN wire is good for conduit with multiple wires ... but stranded cannot be installed under screw terminals on outlets, switches, timers etc without risk ... of heat causing splayed strands ....that come loose ... and begin to arc. Connect stranded to short piece of solid copper wire, and attach solid to screw terminal. Do not solder residential or commercial wiring. Project wire, extension cords, thermostat, bell and automotive wire are not rated for residential or commercial wiring. Only wire maked 600 volt can be used for permanent household wiring. Buy: Southwire 600 volt stranded wire Rolls of stranded wire HOOK UP Wires |
 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 Electric Wire Stripping Machine Linesman pliers Utility knife at Amazon |
 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 |
 GFCI circuit breaker A GFCI circuit breaker will protect all boxes on circuit. Circuit must be grounded. Ground wire must be continuous and connected to each piece of equipment. White wire on circuit breaker must be connected to Neutral busbar inside the breaker panel. Buy GFCI circuit breakers |
Push down 1" wide Push down breaker Plug-in breaker Buy single-pole: Choose from 15 to 60 amp Eaton CL series Siemens 15-60 amp Single-pole tandem breaker Tandem breakers |
Push down 2" wide Push down breaker Plug-in breakers Buy double-pole: Choose from 15 to 125 amp Choose from 15 amp to 200 amp Eaton CL series circuit breaker Siemens circuit breaker Double pole GFCI |
 Volts x Amps = Watts Amps = Watts divided by Volts Typical motor starting currents of 6 to 8 times normal running current when starting. |
Motor amp draw Buy: AO smith / Century / motors at Amazon Dayton motors at Amazon Electric motors at Amazon Draft inducer blowers for gas appliance + water heater Water pumps at Amazon Wet dry vacs Resources: Motors can run 10% more or 10% less than rated voltage AO Smith motors with troubleshoot and wiring .pdf AO Smith motor wiring Magnetec motors is AO Smith, AO Smith motors are now Century 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 Dayton Motors: Dayton Manufacturing is owned by WW Grainger. Contact Grainger. Always connect ground wire. |
| " Current capacity must be adequate enough to maintain
rated voltage at the motor terminals under all conditions. If it’s 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 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. |
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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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Length of wire/ amp draw Use larger wire and breaker with longer distance |
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Single-phase/
3-phase Wire and Breaker size chart |
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Single-phase/ 3-phase Amp load by Kilowatt |
 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. Each motor has a label with a locked-rotor code that is needed for the calculation. Use chart below. 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 or KW ... how much power the motor delivers. The locked rotor code is used to calculate the inrush or amperage needed for that specific motor during start up. The example problem on left shows 50 HP 3-phase 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: 7.1 x 50 HP = 355 KWA or KW at start up 355 KW = 355,000 watts P (power or watts) = E (volts) x I (amperage) x .173 1.73 is the square root of 3, used for 3-phase calculations. 355,000 watts = 480 volts x I (unknown amps) x 1.73. Solve for amps: I = 355,000 ÷ 480 x 1.73  Residential single-phase motors also have inrush. This is generally not an issue when calculating household wire and breaker size since the HP rating is relatively small, start-up is brief, and circuit breaker doesn't react fast enough to trip with the small surge of amperage (heat) on the wire. However large swimming pool motors, and other application that use 3-5 HP motors should have oversized wire and breaker to supply ample electricity for start. Resources: Locked rotor KVA nameplate rating: Calculate inrush .pdf Difference between single-phase and 3-phase Color code for wire |
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Water heater; recommended Circuit Breaker size/ non-simultaneous Residential water heaters are non-simultaneous. Tank label will show type of operation. Resource: How electric water heaters work 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 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. Resources: How to wire water heater elements and thermostats How to wire tankless electric water heater |
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Water
heater Amp draw/ non-simultaneous Residential water heaters are non-simultaneous Same as chart above except showing actual amp draw instead of recommended breaker size Resources 3 phase water heater |
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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 |
 Outdoor motors, pumps, equipment, metal subpanels, boxes etc must be connected to main panel ground wire, and can be bonded to a separate ground rod as back up. Do not touch metal electrical equipment if power is ON. Use ohmmeter to verify resistance between earth and motor frame is less than 0.5 Ω Resource Why you need ground wire |
 Inspect the ground connection at ground rod  If the ground wire is disconnected from
ground rod, DO NOT reconnect the ground unless main breaker is
de-energized.Do not touch or remove ground rod. |
 Household NM-B Wires are color-coded so inspectors/ electricians can easily identify which wire is used during construction 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.  |
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. 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. 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. Use 600 volt solid copper wire only Do not use stranded wire inside main breaker box or any permanent box. Stranded wire can be used for connectors and plugs. Do not use extension cord for permanent household wiring Extension cords are used for connectors and plugs only. Read more about uses for extension cords 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. Aluminum wire expands when electricity travels through wire. Expansion causes loose connections and fire hazard. Rating for short lengths 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 |
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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 |
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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 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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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 imageUse in-line fuse when connecting 2 different gauge wires Illustration shows smaller 12-2 cable connected to larger 10-3 cable. The 10 gauge wire carries 240 volt plus a Neutral wire, and is protected by 30 amp breaker The amp draw on 30 amp breaker is too large for 12 gauge wire. 12 gauge wire should have 20 amp breaker. Connect smaller
12 gauge wire to 10 gauge wire using twist on wire connector. All
connections must be inside electrically rated enclosed box with cover.
Use fuseholder with 20 amp fuse.Fuse will protect entire length of 12 gauge wire. Connect fuse to Hot wire. Never put fuse on Neutral ... the Neutral wire must never be switched off, and must run continuous throughout installation. If the 12 gauge wire is wired for 240V, instead of 120V shown in illustration, then fuses can be added to both hot wires. Always make connections inside a box with cover Buy: Panel mount fuse holders at Amazon ANL fuseholder Buy fuseholders Din rail fuseholder 10 x 38 mm fuse Electrical terminals Solder guns Resource: See fuseholder |
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 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 |
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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. That is called dedicated circuit, and dedicated breaker. - Each 240 volt circuit is usually 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. Resources: See inside main breaker box 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 |
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What is 3-phase electric: power plant to end
user
How to wire 3-phase timer 3-phase water heater |
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Buy Electronic parts Industrial supplies Tools and home improvement Home and garden Hayward pool Pentair pool Southwire electric |
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Buy
Tools DEWALT Black and Decker Stanley SKIL Makita Porter-Cable Bosch Irwin Hand tools Klein hand tools Fluke electrical testing Dremel hobby tools Campbell Hausfeld air powered Tekton automotive Powerbuilt automotive Saws and saw blades |
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Resource: Compare box timers DPDT timers Intermatic Control water heater w/ Z-wave |
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Resource: Intermatic control centers: and parts Digital control centers and parts Tork control centers and parts Subpanels All control centers and parts Enclosures |
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Resource: Programmable timers Countdown timers Off delay timers On delay timers Timer modules Din rail Twin & one-shot Woods Intermatic Tork |
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Recirculation systems |
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