Solved Examples of Proper Wire & Cable Size

Following are the examples of determining the proper Size of cables for electrical wiring
installation which will make it easy to understand the method of “how to determine the
proper size of cable for a given load”.
Example 1 … (Imperial, British or English System)
For Electrical wiring installation in a building, Total load is 4.5kW and total length of
cable from energy meter to sub circuit distribution board is 35 feet. Supply voltages are
220V and temperature is 40°C (104°F). Find the most suitable size of cable from energy
meter to sub circuit if wiring is installed in conduits.
Solution:-
 Total Load = 4.5kW = 4.5 x1000W = 4500W
 20% additional load = 4500 x (20/100) = 900W
 Total Load = 4500W + 900W = 5400W
 Total Current = I = P/V = 5400W /220V =24.5A
Now select the size of cable for load current of 24.5A (from Table 1) which is 7/0.036
(28 Amperes). It means we can use 7/0.036 cable according to table 1.
Now check the selected (7/0.036) cable with temperature factor in Table 3, so the
temperature factor is 0.94 (in table 3) at 40°C (104°F) and current carrying capacity of
(7/0.036) is 28A, therefore, current carrying capacity of this cable at 40°C (104°F) would
be;
Current rating for 40°C (104°F) = 28 x 0.94 = 26.32 Amp.
Since the calculated value (26.32 Amp) at 40°C (104°F) is less than that of current
carrying capacity of (7/0.036) cable which is 28A, therefore this size of cable (7/0.036)
is also suitable with respect to temperature.
Now find the voltage drop for 100 feet for this (7/0.036) cable from Table 4 which is 7V,
But in our case, the length of cable is 35 feet. Therefore, the voltage drop for 35 feet
cable would be;
Actual Voltage drop for 35 feet = (7 x 35/100) x (24.5/28) = 2.1V
And Allowable voltage drop = (2.5 x 220)/100 = 5.5V
Here The Actual Voltage Drop (2.1V) is less than that of maximum allowable voltage
drop of 5.5V. Therefore, the appropriate and most suitable cable size is (7/0.036) for
that given load for Electrical Wiring Installation.
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Phase)
Example 2 … (SI / Metric / Decimal System)
What type and size of cable suits for given situation
 Load = 5.8kW
 Volts = 230V AV
 Length of Circuit = 35 meter
 Temperature = 35°C (95°F)
Solution:-
Load = 5.8kW = 5800W
Voltage = 230V
Current = I = P/V = 5800 / 230 = 25.2A
20% additional load current = (20/100) x 5.2A = 5A
Total Load Current = 25.2A + 5A = 30.2A
Now select the size of cable for load current of 30.2A (from Table 1) which is 7/1.04 (31
Amperes). It means we can use 7/0.036 cable according to the table 1.
Now check the selected (7/1.04) cable with temperature factor in Table 3, so the
temperature factor is 0.97 (in table 3) at 35°C (95°F) and current carrying capacity of
(7/1.04) is 31A, therefore, current carrying capacity of this cable at 40°C (104°F) would
be;
Current rating for 35°C (95°F) = 31 x 0.97 = 30 Amp.
Since the calculated value (30 Amp) at 35°C (95°F) is less than that of current carrying
capacity of (7/1.04) cable which is 31A, therefore this size of cable (7/1.04) is also
suitable with respect to temperature.
Now find the voltage drop for per ampere meter for this (7/1.04) cable from (Table 5)
which is 7mV, But in our case, the length of cable is 35 meter. Therefore, the voltage
drop for 35 meter cable would be:
Actual Voltage drop for 35meter =
= mV x I x L
= (7/1000) x 30×35 = 7.6V
And Allowable voltage drop = (2.5 x 230)/100 = 5.75V
Here the actual Voltage drop (7.35V) is greater than that of maximum allowable voltage
drop of 5.75V. Therefore, this is not a suitable size of cable for that given load. So we
will select the next size of selected cable (7/1.04) which is 7/1.35 and find the voltage
drop again.
According to Table (5) the current rating of 7/1.35 is 40 Amperes and the voltage drop in
per ampere meter is 4.1 mV (See table (5)). Therefore, the actual voltage drop for 35
meter cable would be;
Actual Voltage drop for 35 meter =
= mV x I x L
(4.1/1000) x 40×35 = 7.35V = 5.74V
This drop is less than that of maximum allowable voltage drop. So this is the most
appropriate and suitable cable or wire size.
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Example 3
Following Loads are connected in a building:-
Sub-Circuit 1
 2 lamps each o 1000W and
 4 fans each of 80W
 2 TV each of 120W
Sub-Circuit 2
 6 Lamps each of 80W and
 5 sockets each of 100W
 4 lamps each of 800W
If supply voltages are 230 V AC, then calculate circuit current and Cable size for
each Sub-Circuit?
Solution:-
Total load of Sub-Circuit 1
= (2 x 1000) + (4 x 80) + (2×120)
= 2000W + 320W + 240W = 2560W
Current for Sub-Circuit 1 = I = P/V = 2560/230 = 11.1A
Total load of Sub-Circuit 2
= (6 x 80) + (5 x 100) + (4 x 800)
= 480W + 500W + 3200W= 4180W
Current for Sub-Circuit 2 = I = P/V = 4180/230 = 18.1A
Therefore, Cable suggested for sub circuit 1 = 3/.029” (13 Amp) or 1/1.38 mm (13
Amp)
Cable suggested for Sub-Circuit 2 = 7/.029” (21 Amp) or 7/0.85 mm (24 Amp)
Total Current drawn by both Sub-Circuits = 11.1A + 18.1A = 29.27 A
So cable suggested for Main-Circuit = 7/.044″ (34 Amp) or 7/1.04 mm (31 Amp)
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Example 4
A 10H.P (7.46kW) three phase squirrel cage induction motor of continuous rating using
Star-Delta starting is connected through 400V supply by three single core PVC cables
run in conduit from 250feet (76.2m) away from multi-way distribution fuse board. Its full
load current is 19A. Average summer temperature in Electrical installation wiring is 35°C
(95°F). Calculate the size of the cable for the motor?
Solution:-
 Motor load = 10H.P = 10 x 746 = 7460W *(1H.P = 746W)
 Supply Voltage = 400V (3-Phase)
 Length of cable = 250feet (76.2m)
 Motor full load Current = 19A
 Temperature factor for 35°C (95°F) = 0.97 (From Table 3)
Now select the size of cable for full load motor current of 19A (from Table 4) which is
7/0.36” (23 Amperes) *(Remember that this is a 3-phase system i.e. 3-core cable) and
the voltage drop is 5.3V for 100 Feet. It means we can use 7/0.036 cable according
Table (4).
Now check the selected (7/0.036) cable with temperature factor in table (3), so the
temperature factor is 0.97 (in table 3) at 35°C (95°F) and current carrying capacity of
(7/0.036”) is 23 Amperes, therefore, current carrying capacity of this cable at 40°C
(104°F) would be:
Current rating for 40°C (104°F) = 23 x 0.97 = 22.31 Amp.
Since the calculated value (22.31 Amp) at 35°C (95°F) is less than that of current
carrying capacity of (7/0.036) cable which is 23A, therefore this size of cable (7/0.036) is
also suitable with respect to temperature.
Load factor = 19/23 = 0.826
Now find the voltage drop for 100feet for this (7/0.036) cable from table (4) which is
5.3V, But in our case, the length of cable is 250 feet. Therefore, the voltage drop for 250
feet cable would be;
Actual Voltage drop for 250feet = (5.3 x 250/100) x 0.826 = 10.94V
And maximum Allowable voltage drop = (2.5/100) x 400V= 10V
Here the actual Voltage drop (10.94V) is greater than that of maximum allowable
voltage drop of 10V. Therefore, this is a not a suitable size of cable for the given load.
So we will select the next size of selected cable (7/0.036) which is 7/0.044 and find the
voltage drop again. According to Table (4) the current rating of 7/0.044 is 28 Amperes
and the volt drop in per 100 feet is 4.1V (see Table 4). Therefore, the actual voltage
drop for 250 feet cable would be;
Actual Voltage drop for 250 feet =
= Volt drop per 100 feet x length of cable x load factor
= (4.1/100) x 250 x 0.826 = 8.46V
And Maximum Allowable voltage drop = (2.5/100) x 400V= 10V
The actual voltage drop is less than that of maximum allowable voltage drop. So this is
the most appropriate and suitable cable size for electrical wiring installation in a given
situation.
NEC Wire Size Table 310.15(B)(16) (formerly Table
310.16) & Chart
NEC (National Electrical Code) Table 310.15(B)(16) (formerly Table 310.16) – 310.60 –
ARTICLE 310 – Conductors for General Wiring & Allowable Ampacities of Conductors &
Wire Sizes based on AWG (American Wire Gauge).
310.60               ARTICLE 310 — CONDUCTORS FOR GENERAL WIRING
Table 310.15(B)(16) (formerly Table 310.16) Allowable Ampacities of Insulated
Conductors Rated Up to and Including 2000 Volts, 60°C Through 90°C (140°F
Through 194°F), Not More Than Three Current-Carrying Conductors in Raceway,
Cable, or Earth (Directly Buried), Based on Ambient Temperature of 30°C (86°F)*

Size Temperature Rating of Conductor [See Table 310.104(A).] Size

AWG 60°C 75°C 90°C AWG
or 60°C 75°C or
(140°F (167°F (194°F 90°C (194°F)
(140°F) (167°F)
kcmil ) ) ) kcmil
Types Types Types Types Types Types TBS, SA,
TW, RHW, TBS, TW, UF RHW, SIS, THHN,
UF THHW SA, THHW, THHW,
, THW, SIS, THW, THW-2, THWN-
THWN FEP, THWN,
, FEPB, XHHW, 2, RHH, RHW-2,
XHHW MI, USE USE-2, XHH,
 RHH,
RHW-
2,
THHN,
THHW
,
THW-
2,
THWN
, USE, -2, XHHW, XHHW-2,
ZW ZW-2
USE-
2,
XHH,
XHHW
,
XHHW
-2,
ZW-2
ALUMINUM OR COPPER-CLAD
COPPER
ALUMINUM
18** — — 14 — — — —
16** — — 18 — — — —
14** 15 20 25 — — — —
12** 20 25 30 15 20 25 12**
10** 30 35 40 25 30 35 10**
8 40 50 55 35 40 45 8
6 55 65 75 40 50 55 6
4 70 85 95 55 65 75 4
3 85 100 115 65 75 85 3
2 95 115 130 75 90 100 2
1 110 130 145 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
300 240 285 320 195 230 260 300
350 260 310 350 210 250 280 350
400 280 335 380 225 270 305 400
500 320 380 430 260 310 350 500
600 350 420 475 285 340 385 600
700 385 460 520 315 375 425 700
750 400 475 535 320 385 435 750
800 410 490 555 330 395 445 800
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 525 625 705 435 520 585 1500
1750 545 650 735 455 545 615 1750
2000 555 665 750 470 560 630 2000
    *Refer to 310.15(B)(2) for the ampacity correction factors where the ambient
temperature is other than 30°C (86°F). Refer to 310.15(B)(3)(a) for more than three
current-carrying conductors.
    **Refer to 240.4(D) for conductor overcurrent protection limitations.

Here is the NEC table as a chart (image format to downloads as a reference)

Click image to enlarge
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