AC Station Service Systems –

Physical Design

Contents
AC Station Service Systems – Physical Design ............................................................................................. 1
Overview .................................................................................................................................................... 2
Design Procedure........................................................................................................................................ 2
AC Equipment Selection Criteria ............................................................................................................... 3
Primary Fused Disconnect .......................................................................................................................... 3
Safety Switch .............................................................................................................................................. 4
AC Distribution Cabinet ............................................................................................................................. 5
Station Service Transformers ..................................................................................................................... 6
Standard Transformer KVA-Single Phase .................................................................................................. 6
Standard Transformer KVA-Three Phase ................................................................................................... 6
Voltage Ratings-Standard ........................................................................................................................... 6
Transformer Connections – Single Phase ..................................................................................................10
Transformer Connections – Three Phase ...................................................................................................11
Transformer Loading .................................................................................................................................14
Design Considerations ...............................................................................................................................15
Dual Station Service Schemes ...................................................................................................................15
Cable Sizing ...............................................................................................................................................16
Record of Revision ....................................................................................................................................22

Southern Company Substation Design Criteria Manual AC Station Service Systems – Physical
Design • 1
Overview
The AC station service system supplies all the substation AC power
requirements for the following loads found in a typical substation:
• Power transformer equipment; cooling fans, oil pumps, load
tap changers, cabinet heaters, and receptacles
• Circuit breaker charging motors and heaters
• Switch motor operator heaters
• Outdoor lighting and receptacles
• Control house equipment
 Lighting and receptacles
 Heating, ventilating, and air conditioning
 Battery charger

The following equipment/material comprises the station service system:

• Primary fused disconnect
• Station service transformer
• Safety switch
• Indoor breaker or outdoor fused distribution cabinet
• Cables to equipment

On several older substations, typically ones built before SCADA, two

(2) station service transformers were utilized, with one connected to
phase 1 and the other connected to phase 3. The transformers provided
station service and also potential for the bank metering. An automatic
transfer switch was installed between the two transformers to
automatically switch the station service load between the normal and
emergency sources. This would allow uninterrupted service for critical
circuits like transformer cooling and battery charger supply. With the
installation of SCADA, critical circuits can be monitored by the local
control center. This allows the installation of a single station service
transformer to provide the AC load requirements for the substation.

Design Procedure
The basic design procedure for determining the component
requirements for an AC station service is as follows:
1. A preliminary load study is to be performed to determine the
number of circuits required, the size and rating of the circuit
breakers/fuses needed, the kVA and secondary voltage rating of
the station service transformer(s). If load requirements are
unknown, historical data should be used. Plans for future
expansion of the substation should also be considered in
determining these requirements.

AC Station Service Systems – Physical Design Southern Company Substation Design

Criteria Manual • 2
 2. Calculate the maximum short circuit values that the circuit
breakers and fuses must interrupt during a fault using the known
physical parameters of distance, cable size and transformer
impedance.
3. Select equipment based on the results of the above.
4. Update loads with actual values as available and adjust equipment
requirements if necessary.

AC Equipment Selection Criteria

Primary Fused Disconnect
The primary fuse may be a current-limiting type such as the Cooper
Type ELF or a power type such as the S&C SMD-20, depending on the
application. For all new installations, the Cooper type ELF fuse unit
shall be installed. The selection of the fuse should consider the
following:

• Current rating

• Voltage rating

• Interrupting rating

• Coordination

• Station Service Fuse Recommendations

Current Rating
The current rating of the station service fuse will be provided by the
protective equipment applications group.

Voltage Rating
The station service fuse must be selected on the basis of actual service
voltage. If over insulation is required, then insulators should be
specified to provide the higher rating.

Interrupting Rating
The interrupting-rating of power fuses should equal or exceed the
maximum short circuit at the point in the system where the fuses are to
be installed.

Coordination
For a standard distribution substation with differential relaying, the
station service fuse must coordinate with the relaying such that a station
service fault will be cleared by the station service fuse before the
differential relay operates. A current limiting fuse is required for this
coordination. See the topic on station service fuse recommendations in
the P&C section of the DCM.

Southern Company Substation Design Criteria Manual AC Station Service Systems – Physical
Design • 3
 For a standard distribution substation without differential relaying, the
less expensive power fuse may be used. This station service fuse must
coordinate with the high side protective device, e.g. circuit switcher or
fuses.

Station Service Fuse Recommendations

Station Service Fuse- Cooper “ELF”
13.09kV Substations (7560/240/120V S.S. transformers)
8.3kV Fuse (Catalog # FAK43W6) -for use in 15kV,
125kV BIL Cutout
15kVA transformer 6A
25kVA transformer 6A
26.18kV Substations (15120/240/120V S.S. transformers)
15kV Fuse (Catalog # FAK44W6) -for use in
15/27kV, 125kV BIL Cutout
15kVA transformer 6A
25kVA transformer 6A

Installation - One Bank Distribution Substation

In the standard one bank distribution substation, the station service fuse
will be connected to the load side of the low side bank switch. When
the bank is out of service, the bus could be back fed from the
distribution system and station service would be available for
maintaining the battery charger and other AC loads.

Installation - Two Bank Distribution Substation

In the standard two bank distribution substation for APC, Gulf, and
MPC, the station service fuses will be connected to the load side of the
low side bank switch.
In the standard two bank distribution substation for GPC, the station
service fuses will be connected to the transformer side of the low side
bank switches.
The actual phase connection of each bank’s station service fuse may
vary depending on substation specific needs.
For the standard distribution substation, see standard drawing SMP-
0025 sheet D-7 for fuse mounting details.

Safety Switch
A station service safety switch is required at all substations. This
switch is inserted between the secondary of the station service
transformer and the distribution cabinet. In most cases it is mounted
directly below the station service transformer, on the same structure
leg. The secondary leads from the station service transformer shall be
600V insulated copper cable, sized to the output of the station service
transformer (see formulas below), and will be connected to a safety
switch through a weather head and adequately sized conduit. The

AC Station Service Systems – Physical Design Southern Company Substation Design

Criteria Manual • 4
 safety switch should be a 3-wire (single phase) or 4-wire (three phase),
240V AC rated, with ampacity 30A or larger as required.
The following formulas can be used to size the safety switch:
1φ load current = 1000 (1φ kVA) / phase to phase volts
3φ load current = 1000 (3φ kVA) / (1.732 x phase to phase volts)
Example 1.
1φ safety switch for 15kVA transformer = 1000 (15kVA) / 240V
= 62.5A = use a 60A 1φ safety switch
Example 2.
1φ safety switch for 25kVA transformer = 1000 (25kVA)/240V
= 104A = use a 100A 1φ safety switch

Example 3.
3φ safety switch for (3-100kVA) transformer
= 1000 (300kVA) / (240V x 1.732)
= 722A = use an 800A3φ-safety switch

The standard distribution substation with switch house and 25kVA

distribution transformer will use a heavy duty class 3110, 240V, 100A,
3-wire, visible blade safety switch in a NEMA 3-R enclosure, such as
Square D type H223NRB (or equivalent) with a bolt-on waterproof
hub. The circuit should be fused with 100A NR fuses, sized per the
safety switch rating. The secondary leads from the station service
transformer shall be sized No. 2 AWG (min) for the X, Y, and M
conductor. The circuit to the switch house distribution cabinet will exit
the bottom of the safety switch through adequately sized conduit.
The standard distribution without switch house and with a 15kVA
distribution transformer will use a 60A, 3-wire, visible blade safety
switch in a NEMA 3R enclosure, such as Square D type H222NRB (or
equivalent) with a bolt-on waterproof hub. The circuit should be fused
with 60A NR fuses. The secondary leads from the station service
transformer shall be sized No. 2 AWG (min) for the X, Y, and M
conductor. The circuit to the outdoor distribution cabinet, mounted
directly below, will exit the bottom of the safety switch through
adequately sized conduit.

AC Distribution Cabinet
An AC distribution cabinet is required at all substations where AC
power is needed. The distribution cabinet may be indoor or outdoor. It
should be sized to accommodate the maximum number of branch
circuits anticipated while leaving room for additional growth. The
branch circuit protective devices, breakers or fuses, should be sized to
protect the conductors of the branch circuit from overcurrent
conditions. The protective devices should also have the short circuit
current rating to interrupt the available fault current at the device. In

Southern Company Substation Design Criteria Manual AC Station Service Systems – Physical
Design • 5
 most cases, particularly on smaller station service transformers, the
available secondary fault current will be well below standard breaker
interrupting ratings.
A typical distribution substation will have a 3 wire, 225A main bus
cabinet, main lugs only (no main breaker), such as the Square D type
NQOD42L225CU with type QO circuit breakers. Future substation
expansion may dictate the need to initially install a larger cabinet, e.g.-
54 pole rather than 42 pole capacity.

Station Service Transformers

Standard Transformer KVA-Single Phase
For single phase 120/240V operation, a standard distribution
transformer 15kVA or larger is used. The station service transformer is
connected to the main bus through a disconnecting type fuse. This
single phase supply can also be provided with a power voltage
transformer.
For the standard distribution substation (fused or with circuit switcher)
without a switch house, a 15kVA or larger (typically a 25kVA)
transformer will generally be adequate to supply all station service
requirements.
For the standard distribution substation (circuit switcher) with a switch
house, a 25kVA transformer will generally be adequate to supply all
station service requirements.
Transmission substations will utilize a 25kVA or larger (typically a
50kVA) transformer.

Standard Transformer KVA-Three Phase

For the standard three phase 120/240V station service supply, two or
three distribution transformers 25kVA or larger are used. These
transformers are connected to the main bus through disconnecting type
fuses. This three phase supply can also be provided with power voltage
transformers or auxiliary transformers on the delta tertiary of
autotransformers.
A 120/208V station service supply connection may also be utilized
based on substation requirements.

Voltage Ratings-Standard
When writing descriptions or the purchase of a distribution transformer
or when applying a distribution transformer based on the description, it
is important to understand the industry standard description format.
E = Winding Voltage
Es = System Voltage (system phase to phase voltage)
Es Y = System Voltage on Wye System
Es Grd Y = System Voltage on a Grounded Wye System

AC Station Service Systems – Physical Design Southern Company Substation Design

Criteria Manual • 6
 Symbol Example
E 12470
E / Es Y 7560 / 13090 Y
E / Es Grd Y 7560 / 13090 Grd Y
Es GrdY / E 13090 Grd Y / 7560
E/2E 120 / 240
2E/E 240 / 120
Ex2E 240 x 480

Delta Voltage
E Example: 12470
Indicates winding voltage (E) = system voltage (Es) - suitable for use
on a ∆−system with a φ−φ voltage of 12470V (E=Es)

Delta or Wye
E / Es Y Example: 7560 / 13090 Y
Indicates a winding voltage of 7560V (E) - suitable for installation on a
Y−system (EsY) with a φ−φ voltage of 13090V or a ∆−system with a
φ−φ voltage of 7560V.

Delta or Wye Grd

E / Es GrdY Example: 7560 / 13090 Grd Y
Indicates a winding voltage of 7560V (E) - suitable for installation on a
Grounded Y−system (ES GrdY) with a φ−φ voltage of 13090V with the
neutral bushing of the transformer effectively grounded. (The winding
has reduced insulation to ground and typically have two bushings of
equal insulation). Suitable for use on a ∆−system with a φ−φ voltage
of 7560V (E=Es)

Wye Grd
Es GrdY / E Example: 13090 Grd Y / 7560
Indicates a winding voltage of 7560V (E) - suitable for installation on a
Grounded Y−system (Es GrdY) with a φ−φ voltage of 13090V with the
neutral bushing of the transformer effectively grounded (The winding
has reduced insulation on the neutral end. Typical of a one bushing
transformer). Not suitable for use on a ∆−system.

Series-Parallel or 3-Wire
E / 2E Example: 120 / 240
Indicates that the transformer has two separate windings of equal rating
(E & kVA) that can be connected in parallel or series, and can be used
for a 3−Wire Service.

Southern Company Substation Design Criteria Manual AC Station Service Systems – Physical
Design • 7
 H1 H2

A D

X3 C B X1

X2

3-Wire
2E / E Example: 240 / 120
Indicates that the transformer has only one winding (2E) that has been
center tapped at the mid-point to provide 3−Wire Service.
H1 H2

X3 X1

X2

Series-Parallel Only
E x 2E Example: 240 x 480
Indicates that the transformer has two separate windings of equal rating
(E & kVA) that can be connected in parallel or series to provide 240
(E) or 480 ( 2E) volt service. Not suitable for 3−Wire Service
H1 H2

X4 X1

X2 X3
AC Station Service Systems – Physical Design Southern Company Substation Design
Criteria Manual • 8
 Voltage Ratings-Typical
High Voltages H V Winding BIL Low Voltages
600/480 120 / 240
2400 / 4160Y 120 / 240
2400 / 4160Y x 7200 /
125kV 120 / 240
12470Y
2520 / 4360Y 120 / 240
7200 / 12470Y 95kV, 125kV 120 / 240
7560 / 13090Y 95kV, 125kV 120 / 240
7620 / 13200Y 95kV, 125kV 120 / 240
7960 / 13800Y 95kV, 125kV 120 / 240
12470 95kV, 125kV 120 / 240
12000 / 20800Y 125kV 120 / 240
13200 / 22860Y 125kV 120 / 240
13800 / 23800Y 150kV 120 / 240
14400 / 25000Y 150kV 120 / 240
19920 / 34500Y 200kV 120 / 240
27720 / 48000Y 250kV 120 / 240

Transformer Polarity
Transformer polarity is used to indicate the voltage and current
relationship between windings. When the voltage on a winding with a
polarity mark has reached a positive peak, any associated winding
marked with polarity will reach a positive voltage peak simultaneously.
When current flows into a winding with a polarity mark, current will
flow out of any associated winding marked with polarity.
Transformer polarity can be either additive polarity or subtractive
polarity. Industry standards require that any single phase distribution
transformer 200kVA and smaller with a high voltage of 8660V or less
is always additive polarity. All single phase transformers larger than
200kVA or with a high voltage winding greater than 8660V are
subtractive polarity.

Transformer Terminal Markings - Single Phase

Industry standards require that the high-voltage terminal marked H1 be
located on the right-hand side of the high voltage group when viewed
facing the highest voltage side of the transformer case. All other H
terminals are brought out in numerical order from right to left with the
exception of an H0 terminal, should one be present, which is always to
the right of the H1.
For additive polarity transformers, the X1 terminal is always on the
right when facing the low-voltage side of the transformer. For
subtractive polarity transformers, the X1 terminal is always on the left
when facing the low-voltage side of the transformer case.

Southern Company Substation Design Criteria Manual AC Station Service Systems – Physical
Design • 9
 Transformer Polarity Test Connections
APPLY
240V

H1 H2

10:1 240V
RATIO READ
24V VM 264V

X2 X1
Additive Polarity
APPLY
240V

H1 H2

10:1 240V
RATIO READ
24V VM 216V

X1 X2
Subtractive Polarity

Great care should be taken to insure that the test voltage is always
applied to the highest voltage winding.

Transformer Connections – Single Phase

AC Station Service Systems – Physical Design Southern Company Substation Design

Criteria Manual • 10
 Transformer Connections – Three Phase
Open Delta Connections for 120/240 Volt Service
The open delta bank is often the most economical choice for serving
small three phase loads particularly when commonly available
distribution transformers can be used. The cost of the additional KVA
capacity in the two transformers will normally be much less than the
cost of an additional transformer, fuse, and installation labor.
Open delta banks will carry 57.7% of the equivalent three phase
capacity.
Example:
3- 25kVA transformers, 3 phase capacity = 75kVA.
2- 25kVA transformers, 3 phase capacity = 57.7% of 75kVA or
43.275kVA
Additive polarity transformers are shown in the illustration below.
Electrically the connections will be the same for subtractive polarity
transformers. The connections should be made according to the
labeling of the phases and the bushings.

A
B
C
H1 H2 H1 H2

A D D
X3 X1 X3 A
C B C B X1

X2
a
n
b
c

Delta-Delta Connections for 120/240 Volt Service

The delta-delta connection is the most commonly used three phase
station service connection. All three of the transformers should have
the same impedance, voltage ratio, and taps (if available). If the
transformers do not have the same ratio and taps, circulating currents
can result, that can significantly reduce the capacity of the bank. One of
the transformers will normally have the center tap grounded and will be
used for serving 120/240V single phase load. The transformer carrying
the 120/240V load should be sized to carry the three phase load in

Southern Company Substation Design Criteria Manual AC Station Service Systems – Physical
Design • 11
 addition to the single phase load and may be larger than the other
transformers in the bank, however, it is more common to size all of the
transformers the same to allow for greater flexibility during
emergencies.

A
B
C
H1 H2 H1 H2 H1 H2

A D D D
X3 X1 X 3 A X1 X 3 A X1
C B C B C B

X2
a
n
b
c

Wye-Delta Connections for 120/240 Volt Services

Wye-delta connections for station service are normally avoided in
distribution substations. When the wye is connected to the neutral, the
bank becomes a source for ground fault current and will allow triple
harmonic currents to circulate in the delta for unbalanced voltage
conditions.
For transmission applications, the wye-delta connection is the most
commonly used connection when power potential transformers are used
to provide station service.

AC Station Service Systems – Physical Design Southern Company Substation Design

Criteria Manual • 12
 Delta-Wye for 120/208Y or 277/480Y Volt Service
The delta-wye connection is a connection mostly associated with the
use of a three phase pad mount transformer for station service. The
selection of voltage in this case is based on the three phase load to be
connected to the bank such as transformer fans and pumps. The
decision as to which secondary voltage to use may also be based on the
total station connected load. For large total connected loads it may not
be economically feasible or practical to use 120/208 due to large
switchgear and cable sizes. In those cases it would be more feasible to
use 277/480 and, if need be, step the voltage down at the point of
utilization.
Each transformer will carry 1/3 of the three phase load. All single phase
load should be distributed evenly across each of the transformers. This
will ensure that no one transformer is more loaded than the other
causing one unit on the bank to become overloaded.

Wye-Wye for 120/208Y or 277/480Y Volt Service

The use of the wye-wye connection and the rating of the transformers is
the same as the delta-wye. The only difference is the primary
connection. The wye-wye connection is the typical connection used
when pole type transformers are used for wye connected station
service.

Southern Company Substation Design Criteria Manual AC Station Service Systems – Physical
Design • 13
 Transformer Loading
Single Phase Amperes @ 120/240 Volts

A A A

Single Phase Amperes

Transformer @120/240 Volts
KVA A
10 41.7
15 62.5
25 104
37.5 156
50 208
75 312.5
100 417

Three Phase Amperes @ 120/240 Volt

A A A A A A

B A B B

AC Station Service Systems – Physical Design Southern Company Substation Design

Criteria Manual • 14
 Single Phase Amperes
Transformer @120/240 Volts
KVA

A B
15 62.5 108
25 104 180
37.5 156 270
50 208 360
75 312.5 542
100 417 723

Three Phase Amperes @ 120/208 Volts

A A

A A A
Single Phase Amperes
Transformer @120/208 Volts
KVA A
10 83.3
15 125
25 208
37.5 313
50 417
75 625
100 833

Design Considerations
Dual Station Service Schemes
Overview
As substations increase in size, the need to maintain station service
becomes more critical. Dual station service schemes will need to be
considered taking into account economics and customer service. If a
dual feed is required, the two independent sources must be located so
that the loss of one will not affect the other. Various schemes and
sources are discussed in the following sections.

Southern Company Substation Design Criteria Manual AC Station Service Systems – Physical
Design • 15
 Two Bank Standard Distribution Substation
When a second bank is added to a substation a duplicate station service
system is to be provided. A primary fuse, station service transformer,
and safety switch should be provided on the new bank as duplicate
equipment. A single phase, station service transfer switch is to be
added between the two station services systems with the output of the
transfer switch connected to the AC distribution cabinet. The ampere
rating of the transfer switch should match the rating of the safety
switch.
An automatic transfer switch is designed to transfer the station service
load when the normal supply voltage drops below 70% and to re-
transfer when normal voltage supply is 90% or higher. See section
“Installation – Two Bank Distribution Substation” for typical station
service transformer installation practices.

Transmission Substations with Dual Station Service

Transmission substations should always have two independent AC
station service sources with a transfer switch. The transfer switch will
be single phase or three phase based on the station service voltage. The
ampere rating of the transfer switch should also match that of the safety
switch. The order of preference for station service sources is as follows:
1. Autotransformer Tertiary
2. Low-Side Bus
3. Distribution Line
4. Power Potential Transformer
5. Diesel/Propane Generator
Although these are the preferred sources, it should be noted that the
sources chosen should be based on reliability and strength of the
source.

Cable Sizing
Ampacity
The ampacity of a conductor is the maximum amount of current that it
can carry without raising its temperature above the conductor’s rated
maximum operating temperature. Raising a conductor’s temperature
above its temperature rating will shorten the life of the insulation, or
damage the insulation and eventually cause the cable to fail
prematurely.
The temperature of the conductor is not only a function of cable
construction and loading, it is also a function of the environment in
which the cable is installed. The below table, Table 310.16, from the
National Electrical Code (NEC) gives the ampacity of conductors in
raceway, cable or directly buried.

AC Station Service Systems – Physical Design Southern Company Substation Design

Criteria Manual • 16
Table 310.16 Allowable Ampacities of Insulated Conductors Rated 0 Through 2000 Volts, 60°C
Through 90°C (140°F through 194°F), Not More Than Three Current Carring Conductors in
Raceway, Cable, or Earth (Directly Buried), Based on Ambient Temperature of 30°C (86°F)
Temperature Rating of Conductor [See Table 310.13(A).]
60° (140°F) 75° (167°F) 90° (194°F) 60° (140°F) 75° (167°F) 90° (194°F)
Types TBS, SA, Types TBS, SA,
SIS, FEP, FEPB, SIS, FEP, FEPB,
MI, RHH, RHW- MI, RHH, RHW-
2, THHN, 2, THHN,
Types RHW, THHW, THW-2, Types RHW, THHW, THW-2,
THHW, THW, THWN-2, USE- THHW, THW, THWN-2, USE-
THWN, XHHW, 2, XHH, XHHW, THWN, XHHW, 2, XHH, XHHW,
Types TW, UF USE, ZW XHHW-2, ZW-2 Types TW, UF USE, ZW XHHW-2, ZW-2
Size AWG or Size AWG or
COPPER ALUMINUM OR COPPER-CLAD ALUMINUM
kcmil kcmil
18 - - 14 - - - -
16 - - 18 - - - -
14 20 20 25 - - - -
12 25 25 30 20 20 25 12
10 30 35 40 25 30 35 10
8 40 50 55 30 40 45 8
6 55 65 75 40 50 60 6
4 70 85 95 55 65 75 4
3 85 100 110 65 75 85 3
2 95 115 130 75 90 100 2
1 110 130 150 85 100 115 1
1/0 125 150 170 100 120 135 1/0
2/0 145 175 195 115 135 150 2/0
3/0 165 200 225 130 155 175 3/0
4/0 195 230 260 150 180 205 4/0
250 215 255 290 170 205 230 250
300 240 285 320 190 230 255 300
350 260 310 350 210 250 280 350
400 280 335 380 225 270 305 400
500 320 380 430 260 310 350 500
600 355 420 475 285 340 385 600
700 385 460 520 310 375 420 700
750 400 475 535 320 385 435 750
800 410 490 555 330 395 450 800
900 435 520 585 355 425 480 900
1000 455 545 615 375 445 500 1000
1250 495 590 665 405 485 545 1250
1500 520 625 705 435 520 585 1500
1750 545 650 735 455 545 615 1750
2000 560 665 750 470 560 630 2000
CORRECTION FACTORS
Ambient Temp. For ambient temperatures other than 30°C (86°F), multiply the allowable ampacities shown above by Ambient Temp.
(°C) appropriate factor shown below. (°F)
21-25 1.08 1.05 1.04 1.08 1.05 1.04 70-77
26-30 1.00 1.00 1.00 1.00 1.00 1.00 78-86
31-35 0.91 0.94 0.96 0.91 0.94 0.96 87-95
36-40 0.82 0.88 0.91 0.82 0.88 0.91 96-104
41-45 0.71 0.82 0.87 0.71 0.82 0.87 105-113
46-50 0.58 0.75 0.82 0.58 0.75 0.82 114-122
51-55 0.41 0.67 0.76 0.48 0.67 0.76 123-131
56-60 - 0.58 0.71 - 0.58 0.71 132-140
61-70 - 0.33 0.58 - 0.33 0.58 141-158
71-80 - - 0.41 - - 0.41 159-176

Southern Company Substation Design Criteria Manual AC Station Service Systems – Physical
Design • 17
 Factors That Affect the Ampacity of Cable
Overloads - The NEC requires cables that supply power to
compressors motors, fans, pumps, air conditions, etc. be sized with an
overload factor. The NEC requires that the cables that feed these
devices be sized for 125% of the equipment’s Full Load Rating (not
locked rotor current).
Conductor Temperature Rating - Southern Company control and
power cable is rated 90°C (194°F).
Ambient Temperature - If using NEC Table 310.16 for ambient
temperatures other than 30°C, the correction factors at the bottom of
the table must be applied.
Installation conditions - More than three cables in conduit, ambient
temperature, installation in air, cable, raceway, etc. These conditions
may dictate the use of another ampacity table or the application of a
correction factor.

Voltage Drop
The selection of the minimum size conductor is often limited by
voltage drop considerations. A cable may meet the ampacity
requirements but the voltage drop at the equipment due to cable length
may exceed limits. The voltage drop for power and control circuits
should be limited to 5%.
For substation control and power cables the following formula can be
used to calculate voltage drop:
𝐸𝐸 = 2 ∗ 𝐿𝐿 ∗ 𝐼𝐼 ∗ 𝑍𝑍⁄1000
L= one-way circuit length (ft.)
I= load current (amps)
Z= conductor impedance (Ω/1000ft.)
(See NEC Table 8, Uncoated, Direct Current
Resistance. Note for the purpose of performing our
voltage drop calculations, reactance can be
neglected.)

For three-phase AC circuits, the following formula can be used to

determine phase-to-phase voltage drop:
𝐸𝐸 = 1.73 ∗ 𝐿𝐿 ∗ 𝐼𝐼 ∗ 𝑍𝑍⁄1000
L= one-way circuit length (ft.)
I= load current (amps)
Z= conductor impedance (Ω/1000ft.)
(See NEC Table 8, Uncoated, Direct Current
Resistance. Note for the purpose of performing our
voltage drop calculations, reactance can be
neglected.)

AC Station Service Systems – Physical Design Southern Company Substation Design

Criteria Manual • 18
 Table 8 Conductor Properties

Conductors Direct Current Resistance at 75°C (167°F)

Stranding Overall Copper
Area Diameter Diameter Area Uncoated Coated Aluminum
Size
(AWG
or Circular
kcmil) mm2 mils Quantity mm in. mm in. mm2 in.2 ohm/km ohm/kFt ohm/km ohm/kFt ohm/km ohm/kFt
18 0.823 1620 1 - - 1.02 0.040 0.823 0.001 25.5 7.77 26.5 8.08 42.0 12.8
18 0.823 1620 7 0.39 0.015 1.16 0.046 1.06 0.002 26.1 7.95 27.7 8.45 42.8 13.1
16 1.31 2580 1 - - 1.29 0.051 1.31 0.002 16.0 4.89 16.7 5.08 26.4 8.05
16 1.31 2580 7 0.49 0.019 1.46 0.058 1.68 0.003 16.4 4.99 17.3 5.29 26.9 8.21
14 2.08 4110 1 - - 1.63 0.064 2.08 0.003 10.1 3.07 10.4 3.19 16.6 5.06
14 2.08 4110 7 0.62 0.024 1.85 0.073 2.68 0.004 10.3 3.14 10.7 3.26 16.9 5.17
12 3.31 6530 1 - - 2.05 0.081 3.31 0.005 6.34 1.93 6.57 2.01 10.45 3.18
12 3.31 6530 7 0.78 0.03 2.32 0.092 4.25 0.006 6.50 1.98 6.73 2.05 10.69 3.25
10 5.261 10380 1 - - 2.588 0.102 5.26 0.008 3.984 1.21 4.148 1.26 6.561 2.00
10 5.261 10380 7 0.98 0.038 2.95 0.116 6.76 0.011 4.070 1.24 4.226 1.29 6.679 2.04
8 8.367 16510 1 - - 3.264 0.128 8.37 0.013 2.506 0.764 2.579 0.786 4.125 1.26
8 8.367 16510 7 1.23 0.049 3.71 0.146 10.76 0.017 2.551 0.778 2.653 0.809 4.204 1.28
6 13.30 26240 7 1.56 0.061 4.67 0.184 17.09 0.027 1.608 0.491 1.671 0.510 2.652 0.808
4 21.15 41740 7 1.96 0.077 5.89 0.232 27.19 0.042 1.010 0.308 1.053 0.321 1.666 0.508
3 26.67 52620 7 2.20 0.087 6.60 0.260 34.28 0.053 0.802 0.245 0.833 0.254 1.320 0.403
2 33.62 66360 7 2.47 0.097 7.42 0.292 43.23 0.067 0.634 0.194 0.661 0.201 1.045 0.319
1 42.41 83690 19 1.69 0.066 8.43 0.332 55.8 0.087 0.505 0.154 0.524 0.160 0.829 0.253
1/0 53.49 105600 19 1.89 0.074 9.45 0.372 70.41 0.109 0.399 0.122 0.415 0.127 0.660 0.201
2/0 67.43 133100 19 2.13 0.084 10.62 0.418 88.74 0.137 0.3170 0.0967 0.329 0.101 0.523 0.159
3/0 85.01 167800 19 2.39 0.094 11.94 0.470 111.9 0.173 0.2512 0.0766 0.2610 0.0797 0.413 0.126
4/0 107.2 211600 19 2.68 0.106 13.41 0.528 141.1 0.219 0.1996 0.0608 0.2050 0.0626 0.328 0.100
250 127 - 37 2.09 0.082 14.61 0.575 168 0.260 0.1687 0.0515 0.1753 0.0535 0.2778 0.0847
300 152 - 37 2.29 0.090 16.00 0.630 201 0.312 0.1409 0.0429 0.1463 0.0446 0.2318 0.0707
350 177 - 37 2.47 0.097 17.30 0.681 235 0.364 0.1205 0.0367 0.1252 0.0382 0.1984 0.0605
400 203 - 37 2.64 0.104 18.49 0.728 268 0.416 0.1053 0.0321 0.1084 0.0331 0.1737 0.0529
500 253 - 37 2.95 0.116 20.65 0.813 336 0.519 0.0845 0.0258 0.0869 0.0265 0.1391 0.0424
600 304 - 61 2.52 0.099 22.68 0.893 404 0.626 0.0704 0.0214 0.0732 0.0223 0.1159 0.0353
700 355 - 61 2.72 0.107 24.49 0.964 471 0.73 0.0603 0.0184 0.0622 0.0189 0.0994 0.0303
750 380 - 61 2.82 0.111 25.35 0.998 505 0.782 0.0563 0.0171 0.0579 0.0176 0.0927 0.0282
800 405 - 61 2.91 0.114 26.16 1.030 538 0.834 0.0528 0.0161 0.0544 0.0166 0.0868 0.0265
900 456 - 61 3.09 0.122 27.79 1.094 606 0.940 0.0470 0.0143 0.0481 0.0147 0.0770 0.0235
1000 507 - 61 3.25 0.128 29.26 1.152 673 1.042 0.0423 0.0129 0.0434 0.0132 0.0695 0.0212
1250 633 - 91 2.98 0.117 32.74 1.289 842 1.305 0.0338 0.0103 0.0347 0.0106 0.0554 0.0169
1500 760 - 91 3.26 0.128 35.86 1.412 1011 1.566 0.02814 0.00858 0.02814 0.00883 0.0464 0.0141
1750 887 - 127 2.98 0.117 38.76 1.526 1180 1.829 0.02410 0.00735 0.02410 0.00756 0.0397 0.0121
2000 1013 - 127 3.19 0.126 41.45 1.632 1349 2.092 0.02109 0.00643 0.02109 0.00662 0.0348 0.0106
Notes:
1. These resistance values are valid only for the parameters as given. Using conductors having coated strands,
different stranding type, and , especially, other temperatures changes the resistance.
2. Formula for temperature change: R2 = R1[1 + a (T2-75)] where αcu = 0.00323, αal = 0.00330 at 75°C.

Southern Company Substation Design Criteria Manual AC Station Service Systems – Physical
Design • 19
 Example- Single-Phase AC Circuit
Determine the % voltage drop at startup on a three-wire, single phase,
240VAC circuit supplying a circuit breaker with a 3A heater load and a
spring charge motor in which locked rotor current (starting) equals 33A
and running current is 8A. The circuit consists of a three conductor #6
copper cable 300 ft. long.
Solution:
From Table 8, the resistance of #6 cu. conductor is 0.491Ω/1000ft.
𝐸𝐸 = 2 ∗ 𝐿𝐿 ∗ 𝐼𝐼 ∗ 𝑍𝑍⁄1000
= 2 ∗ 300 ∗ (36) ∗ 0.491⁄1000
= 10.6𝑉𝑉 𝑜𝑜𝑜𝑜 4.4% 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑

Example- Three phase AC Circuit

A power circuit breaker is supplied by a three phase, 4-wire, and
120/240VAC circuit 300 ft. long. There are 10A of single phase load.
The compressor motor is a three phase motor with a starting current of
146A and running current of 21A. The cable is four conductor 2/0
copper. Is this cable of sufficient size?
Solution:
First, check ampacity. Since this circuit is supplying power to a
compressor motor, the running current should be multiplied by 125% to
satisfy NEC requirements.

1.25 𝑋𝑋 (21𝐴𝐴 + 10𝐴𝐴) = 38.7𝐴𝐴

From NEC Table 310-16, 2/0 will carry 195A. The cable ampacity is
good.

Next, check voltage drop.

Treat as worse case three phase load. i.e. 146A starting current plus the
10 single phase load.

From Table 8, the resistance of 2/0 conductor is 0.0967Ω/1000ft.

𝐸𝐸 = 1.73 ∗ 𝐿𝐿 ∗ 𝐼𝐼 ∗ 𝑍𝑍⁄1000
= 1.73 ∗ 300 ∗ 156 ∗ 0.0967/1000
= 7.83𝑉𝑉 𝑜𝑜𝑜𝑜 3.3% 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
The voltage drop on this cable is less than 5%. Therefore from a
voltage drop and ampacity standpoint this cable is acceptable.

AC Station Service Systems – Physical Design Southern Company Substation Design

Criteria Manual • 20
 Voltage Drop Spreadsheet
The attached spreadsheet can also be used to calculate voltage drop to
ensure that the proper conductor size is used to obtain a 5% or less
voltage drop. Click here to load the Voltage Drop Spreadsheet.

Southern Company Substation Design Criteria Manual AC Station Service Systems – Physical
Design • 21
Record of Revision

Rev Description By Date

0 Section separated and reformatted WER 12-27-2011
1 General updates to complete document JWK 09-13-2016

AC Station Service Systems – Physical Design Southern Company Substation Design

Criteria Manual • 22