Compression Connector System

Step One

Preparing the Cable

Wire Stripper shown is Part No. BCS8-40.

33 Strip the insulation carefully to avoid nicking or cutting conductors (wire brush if required). Strands Cut

Nicked Strands

Good Strip

Strip the insulation to the proper length so that conductors can be fully inserted into the connector barrel. Strip Length Too Long

Strip Length Too Short

Strip Length Just Right

Step Two

Determining the Proper Connector

55 Determine the proper Color-Keyed ® Connector for the cable size being used. • • •

Connectors marked with just cable size or CU should be used on copper conductors only. Connectors marked “AL9”*with the cable size should be used on aluminum conductors only. Connectors marked “AL9CU” with the cable size may be used on the aluminum or copper conductors. * Aluminum lugs with a “9” indicate 90 oC rating.

Connectors are marked to show cable size. Cable Size

Step Three

Battpac™ Tool TBM62BSCR shown.

Choosing Tool and Proper Die

77 Die Code Engraving

Select the proper installing die and appropriate tool. T&B Connectors have colored bands or colored dots that correspond to color markings on the dies. Connectors and dies also have a die code number marked or stamped on them. Dies have a code number engraved in the crimp surface

Colored Codes Die Code Marking

Colored Strip

Colored Bands

Step Four

Installation and Inspection Locate tool with correct die in proper position on connector and activate tool. T&B Connectors are banded by colored stripes or engraving to indicate location of die on connector for compression.

Battpac™ Battery Powered Compression TBM62BSCR shown.

Copper

Aluminum

Die located BETWEEN bands

Die located ON Bands

99 When making multiple crimps, make the first crimp nearest the tongue and work towards the barrel end.

When properly crimped, the die code number will be embossed on the connector for easy inspection to determine if correct die and connector combination were used.

Tongue

Thomas & Betts uses “full-width” and “half-width” dies dependent on connector size and tool used. “Half-width” dies are marked with the letter “H” after the die code number.

Barrel

Refer to the instruction sheet supplied with the connectors for information regarding strip length, die selection and number of compressions required.

Die location for compression

1st crimp 2nd crimp

Colored bands

Die code embossed

10

Tool and Die Selection Chart for Power Connectors Connector Size

TBM-8 / 8S

TBM-5 / 5S

TBM8 Die Cat. No.

TBM5 Die Cat. No.

Cat. No. Upper Die

Cat. No. Lower Die

Die Cat. No.

Die Code No.

order 13461

order 13454

13475 13475 13472 13474

13477 13477 13476 13477

11732 11733 11734 11735

21 24 29 33

TBM12D-1 TBM12D-1 TBM12D-2 TBM12D-2

21 24 29 33

order 13462

order 13455

13474 13475 13474 13474

13477 13477 13477 13477

11736 11737 11738 11739

37 42 45 50

TBM12D-3 TBM12D-3 TBM12D-4 TBM12D-4

37 42 45 50

Purple Yellow

order 13463

order 13456

13475 13473

13477 13476

11740 11771

54 62

TBM12D-5 TBM12D-5

54 62

1AWG 1/0 2/0 3/0

Gold Tan Olive Ruby

order 13464

order 13457

13474 13474 13475 13473

13477 13477 13477 13476

11738 11739 11740 11741

45 50 54 60

TBM12D-4 TBM12D-4 TBM12D-5 TBM12D-5

45 50 54 60

4/0 250MCM 300MCM

White Red Blue N/A N/A Brown

13465 13466 13467

13458 4/0 only

13473 13472 13472 13479

13476 13476 13476 13476

11742 11743 11744 11745

66H 71H 76H 80H

TBM12D-5 TBM12D-4 TBM12D-4

66H 71H 76H

13478

13478

11746-TB

87H

TBM12D-3

87H

11747

94H

TBM12D-3

94H 94H

11748 11749 11750 11751 11753

99H 106H 107H 112H 115H

TBM12D-2 TBM12D-2

99H 106H

TBM12D-1 TBM12D-1

112H 115H

Color Keyed Die Groove

Copper

Flex/24

AL/CU

8 AWG 6 AWG 4 AWG 2 AWG

37/24 61/24 91/24 125/24

10AWG 8AWG 6AWG

Red Blue Gray Brown

1 AWG 1/0 2/0 3/0

150/24 225/24 275/24 325/24

4AWG 2AWG

Green Pink Black Orange

4/0 250MCM

450/24 550/24

300MCM 350MCM 400MCM

775/24 (short) 775/24 (long) 925/24*

500MCM 600MCM

350MCM 1100/24

400MCM

1325/24** 700MCM 750MCM 800MCM 900MCM 1000MCM

500MCM 650MCM 1925/24

700MCM 750MCM 800MCM 1000MCM

TBM25S

TBM4S

TBM8-750/-1

C-TAPS ONLY

Green Green Pink Pink Black Orange Purple Yellow

*Standard barrel only. Long barrel requires Brown 87H

**Standard barrel only. Long barrel requires Black 106H

13468

TBM6 / 6S (25000)

13642M (13400) Hydraulic Head

TBM12 Hydraulic Head Die Cat. No. Die Code No.

11

Tool and Die Selection Chart for Power Connectors Connector Size Code Copper

Flex/24

AL/CU

8 AWG 6 AWG 4 AWG 2 AWG 1 AWG 1/0 2/0 3/0 4/0 250MCM

37/24 61/24 91/24 125/24 150/24 225/24 275/24 325/24 450/24 550/24

10AWG 8AWG 6AWG

300MCM 350MCM 400MCM

775/24 (short) 775/24 (long) 925/24*

500MCM 600MCM

4AWG 2AWG

1AWG 1/0 2/0 3/0 4/0 250MCM 300MCM 350MCM

1100/24

400MCM

1325/24** 700MCM 750MCM 800MCM 900MCM 1000MCM

500MCM 650MCM 1925/24

700MCM 750MCM 800MCM 1000MCM

*Standard barrel only. Long barrel requires Brown 87H

Color Keyed Die Groove

TBM6BSCR/6H

TBM62BSCR

TBM14BSCR / 14M / 13100A

TBM15BSCR / 15I***

21940 (40 TON)

Die Cat. No.

Die Code No.

Die Cat. No.

Die Code No.

Die Cat. No.

Die Code No.

Die Cat. No.

Die Code No.

Red Blue Gray Brown Green Pink Black Orange Purple Yellow Gold Tan Olive Ruby White Red Blue N/A N/A Brown

6TON21 6TON24 6TON29 6TON33 6TON37 6TON42 6TON45 6TON50 6TON54 6TON62 6TON45 6TON50 6TON54 6TON60 6TON66 6TON71 6TON76 6TON80

21 24 29 33 37 42 45 50 54 62 45 50 54 60 66H 71H 76H 80H

TBM6221 TBM6224 TBM6229 TBM6233 TBM6237 TBM6242 TBM6245 TBM6250 TBM6254 TBM6262 TBM6245 TBM6250 TBM6254 TBM6260 TBM6266 TBM6271 TBM6276 TBM6280

21 24 29 33 37 42 45 50 54 62 45 50 54 60 66 71 76 80

15520 15522 15527-CK 15528 15513-CK 15508 15526 15530 15511 15510-CK 15526 15530 15511 15532-CK 15534 15514-CK 15512 15517

21 24 29 33 37 42 45 50 54 62 45 50 54 60 66H 71H 76H 80H

6TON87

87H

TBM6287

87

15506

87H

15520 15522 15527-CK 15528 15513-CK 15508 15526 15530 15511 15510-CK 15526 15530 15511 15532-CK 15534 15514-CK 15512 15517 15606 15506

21 24 29 33 37 42H 45 50 54H 62 45 50 54H 60 66H 71H 76H 80H 80 87H

11423

87

Green Green Pink Pink Black Orange Purple Yellow

6TON94

94H

94

94H

94H 94H

11364

15536-CK

15611 15536-CK

15505 15515-CK

99H 106H

15504

115H

15505 15515-CK 15608 15609 15504 15603 15602 15601

99H 106H 107H 112H 115H 125H 140H 150H

11424 74506 11425 11426 11308 11416 11418 11419

99 106 107 112 115 125 140 150

99H 106H 107H 112H 115H

**Standard barrel only. Long barrel requires Black 106H

***15500 Series dies require 15500-TB adapter. 15500F for full size die to fit TBM151 without adapter

Die Cat. No.

Die Code No.

11401 11402 11333 11334 11405 11406 11407 297-31669-7 11405 11406 11407 11408 11409 11363 11410

29 33 37 42 45 50 54H 62 45 50 54 60 66 71 76

12

Tool and Die Selection Chart for Copper H-Taps Conductor Size Code Cable (Flex Cable)

Installation

Main

Branch 1

Branch 2

Branch 3

H-Tap

Color

Die

Tool

# Of Crimps

Die Embossing

Strip Length

Insulating Cover

8-14 (8-14)

8-14 (8-14)

-

-

CHT814-10

Green

15CA37RCH*

Group 1

1

37R

1/2"

HTC2S

2-6 Str/Sol(2-8)

2-6 Str / Sol (2-8)

8-14 (8-14)

8-14 (8-14)

CHT214-9

Brown

15CA71RCH*

Group1

1

71R

7/8"

250-2 (4/0-2)

8-14 (8-14)

8-14 (8-14)

-

CHT250214-8

Purple

15CA80RCH*

Group 2

1

80R

1 1/8"

250-2 (4/0-2)

2-6 Str / Sol (2-8)

8-14 (8-14)

-

CHT25014-7

Purple

15CA80RCH*

Group 2

1

80R

1 1/8"

250-2 (4/0-2)

250-2 (4/0-2)

-

-

CHT2502-6

Purple

15CA80RCH*

Group 2

1

80R

13/16"

500-4/0 (350-4/0)

250-1/0 (4/0-1/0)

1 Str 2-6 (1-8)

8-14 (8-14)

CHT50010-5

Brown

15612CH

Group 2

2

N

1 1/8"

500-4/0 (350-4/0)

500-4/0 (350-4/0)

-

-

CHT50040-4

Brown

15612CH

Group 2

2

N

1 1/8"

750-350 (550-500)

4/0-1/0 (250-1/0)

1 Str 2-6 (1-8)

2-14 (2-14)

CHT75010-3

Yellow

15620CH

Group 2

1

Z

1 1/8"

750-350 (550-500)

750-350 (550-350)

-

-

CHT750350-2

Yellow

15620CH

Group 2

1

Z

1 3/8"

750 (750-500)

350-4/0 STR & FLEX

-

-

CHT75040-11

Yellow

15620CH

Group 2

1

Z

1 1/8"

(750-500) (750)

(750-500) (350)

-

-

CHT750350-1F

White

15620CHF

Group 2

1

F

1 1/8"

*Requires optional adapter 15500-TB when used with hydraulic head TBM15I and TBM15BSCR

Group 1 = TBM15I, TBM15BSCR, TBM14, TBM14BSCR, 13100A

Group 2 = TBM15I, TBM15BSCR

HTC40

HTC500

HTC1000

13

Tool and Die Chart for Standard C-Taps TBM62BSCR

TBM8-750

Branch 1

C-Tap

Color

Die

Die

Die

12 14 10 8 6 8 4 OR 5 6 3 4 OR 5 2 3 4 1 2 3 1/0 1 2 2/0 1/0 1 3/0 2/0 1/0

14 16 10 12 10,12 8,10,12 8, 10, 12 6, 8 6, 8, 10, 12 *** 6, 5 6, 8, 10, 12 5 3 4, 5, 6, 8, 10, 12 4, 5 3, 4 4, 5, 6, 8, 10, 12 3, 4 2, 3 3, 4, 5, 6, 8, 10, 12 2, 3 1, 3 2, 3, 4, 5, 6, 8, 10, 12 1, 2 1/0, 1

54705

Red

6TON21

TBM6221

-

54710

Blue

6TON24

TBM6224

54715

Gray

6TON29

TBM6229

-

54720

Brown

6TON33

TBM6233

TBM8-750C20

54725

Green

6TON37

TBM6237

TBM8-750C2530

54730

Pink

6TON42

TBM6242

TBM8-750C2530

54735

Black

6TON45

TBM6245

TBM8-750C3540

54740

Orange

6TON50

TBM6250

TBM8-750C3540

54745

Purple

6TON54

TBM6254

TBM8-750C4550

54750

Yellow

6TON62

TBM6262

TBM8-750C4550

Group 2

Group 3

Insulation Choice Adhesive Pad

Shrink Tubing

HS12-6

Accommodates this Entire Range

Group 1

Main

Accommodates this Range

Code Wire Comb. Cir. Area Range

HS6-1 AC5X3

HS4-30

*** When using 3 AWG on main and 12 AWG on branch with smart tools and dies, 12 AWG wire must be doubled (hair-pinned) and placed on branch for crimping Group 1 = TBM6H / TBM6BSCR Group 2 = TBM25S, TBM21E and require 2 compressions within each crimp area Group 3 = TBM5 / 5S, TBM6 / 6S, TBM8/8S, TBM6H and require 1 compression within each crimp area

14

Tool and Die Chart for Large C-Taps Code Copper Range

Regular Tools

Smart Tool

Insulation Choice

Main

Branch 1

C-Tap *

Color

Tools

Dies

Die Code

# Of Crimps***

Tools

Die

# Of Crimps

1 1/0 2/0 3/0 4/0 2/0 3/0 4/0 250 2/0 3/0 4/0 250 300 4/0 250 300 350 250 300 350 400 450 500 350 400 450 500 750 500 750/500

1 1/0-2 2/0-4 1/0-6 1-8 2/0-1 3/0-3 4/0-4 1/0-8 2/0-1 3/0-2 4/0-4 3/0-6 2/0-8 4/0-2/0 250-1 4/0-4 3/0-6 250 300-3/0 350-1/0 300-2 250-4 250-6**** 350-4/0 400-2/0 450-1 500-2 4/0-6 4/0-1/0 750-4/0

54755

Blue

13642M TBM12 TBM14M TBM15I 13100A TBM14BSCR TBM15BSCR

11744 TBM12D-4

76H

2

TBM8-750 TBM8-750M-1

TBM8-750CL

1

76

1

87H

2

54760

54765

Brown

Shrink Tubing

15512 ** 11746-TB TBM12D-3 15506 ** 11748 TBM12D-2

Pink

Adhesive Pad

2 HS4-30

99H

15505 ** 54770

Black

54775

Yellow

11749 TBM12D-2 15515-CK ** 11753 TBM12D-1

AC5X7

106H

115H

HS40-400

15504 **

54780

White

TBM15I TBM15BSCR

15603

125H

N/A 54785 N/A

HS500-1000

3 4

54790

*For tin plate finish add "TP" to Cat. No. listed (Example: 54755TP) **Use with adapter Cat. No. 15500-TB (Note: If 15500 dies have a suffix "F", they are full sized dies and can be used with the TBM15I without an adapter.) ***When using compact copper cable, apply additional overlapping crimps so that C-tap is crimped from end to end. 11000 series dies go with 13642M tool, TBM12D-# series dies go with TBM12 tool, and 15500 series dies go with TBM14M/14BSCR/13100A/TBM15I/15BSCR ****#6 AWG branch must be doubled

15

Conductor Properties Conductors

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

Stranding Area

Overall

Diameter

Copper

Diameter

Area

Aluminum

Uncoated

Coated

Size (AWG or kcmil)

mm2

Circular mils

Quantity

mm

in.

mm

in.

mm2

in.2

ohm/km

ohm/kFT

ohm/km

ohm/kFT

ohm/km

ohm/kFT

18 18

0.823 0.823

1620 1620

1 7

— 0.39

— 0.015

1.02 1.16

0.040 0.046

0.823 1.06

0.001 0.002

25.5 26.1

7.77 7.95

26.5 27.7

8.08 8.45

42.0 42.8

12.8 13.1

16 16

1.31 1.31

2580 2580

1 7

— 0.49

— 0.019

1.29 1.46

0.051 0.058

1.31 1.68

0.002 0.003

16.0 16.4

4.89 4.99

16.7 17.3

5.08 5.29

26.4 26.9

8.05 8.21

14 14

2.08 2.08

4110 4110

1 7

— 0.62

— 0.024

1.63 1.85

0.064 0.073

2.08 2.68

0.003 0.004

10.1 10.3

3.07 3.14

10.4 10.7

3.19 3.26

16.6 16.9

5.06 5.17

12 12

3.31 3.31

6530 6530

1 7

— 0.78

— 0.030

2.05 2.32

0.081 0.092

3.31 4.25

0.005 0.006

6.34 6.50

1.93 1.98

6.57 6.73

2.01 2.05

10.45 10.69

3.18 3.25

10 10

5.261 5.261

10380 10380

1 7

— 0.98

— 0.038

2.588 2.95

0.102 0.116

5.26 6.76

0.008 0.011

3.984 4.070

1.21 1.24

4.148 4.226

1.26 1.29

6.561 6.679

2.00 2.04

8 8

8.367 8.367

16510 16510

1 7

— 1.23

— 0.049

3.264 3.71

0.128 0.146

8.37 10.76

0.013 0.017

2.506 2.551

0.764 0.778

2.579 2.653

0.786 0.809

4.125 4.204

1.26 1.28

6 4 3 2 1

13.30 21.15 26.67 33.62 42.41

26240 41740 52620 66360 83690

7 7 7 7 19

1.56 1.96 2.20 2.47 1.69

0.061 0.077 0.087 0.097 0.066

4.67 5.89 6.60 7.42 8.43

0.184 0.232 0.260 0.292 0.332

17.09 27.19 34.28 43.23 55.80

0.027 0.042 0.053 0.067 0.087

1.608 1.010 0.802 0.634 0.505

0.491 0.308 0.245 0.194 0.154

1.671 1.053 0.833 0.661 0.524

0.510 0.321 0.254 0.201 0.160

2.652 1.666 1.320 1.045 0.829

0.808 0.508 0.403 0.319 0.253

16

Conductor Properties (Continued) Conductors

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

Stranding Area

Overall

Diameter

Copper

Diameter

Area

Uncoated

Aluminum Coated

Size (AWG or kcmil)

mm2

Circular mils

Quantity

mm

in.

mm

in.

mm2

in.2

ohm/km

ohm/kFT

ohm/km

ohm/kFT

ohm/km

ohm/kFT

1/0 2/0 3/0 4/0

53.49 67.43 85.01 107.2

105600 133100 167800 211600

19 19 19 19

1.89 2.13 2.39 2.68

0.074 0.084 0.094 0.106

9.45 10.62 11.94 13.41

0.372 0.418 0.470 0.528

70.41 88.74 111.9 141.1

0.109 0.137 0.173 0.219

0.399 0.3170 0.2512 0.1996

0.122 0.0967 0.0766 0.0608

0.415 0.329 0.2610 0.2050

0.127 0.101 0.0797 0.0626

0.660 0.523 0.413 0.328

0.201 0.159 0.126 0.100

250 300 350

— — —

37 37 37

2.09 2.29 2.47

0.082 0.090 0.097

14.61 16.00 17.30

0.575 0.630 0.681

168 201 235

0.260 0.312 0.364

0.1687 0.1409 0.1205

0.0515 0.0429 0.0367

0.1753 0.1463 0.1252

0.0535 0.0446 0.0382

0.2778 0.2318 0.1984

0.0847 0.0707 0.0605

400 500 600

— — —

37 37 61

2.64 2.95 2.52

0.104 0.116 0.099

18.49 20.65 22.68

0.728 0.813 0.893

268 336 404

0.416 0.519 0.626

0.1053 0.0845 0.0704

0.0321 0.0258 0.0214

0.1084 0.0869 0.0732

0.0331 0.0265 0.0223

0.1737 0.1391 0.1159

0.0529 0.0424 0.0353

700 750 800

— — —

61 61 61

2.72 2.82 2.91

0.107 0.111 0.114

24.49 25.35 26.16

0.964 0.998 1.030

471 505 538

0.730 0.782 0.834

0.0603 0.0563 0.0528

0.0184 0.0171 0.0161

0.0622 0.0579 0.0544

0.0189 0.0176 0.0166

0.0994 0.0927 0.0868

0.0303 0.0282 0.0265

900 1000

— —

61 61

3.09 3.25

0.122 0.128

27.79 29.26

1.094 1.152

606 673

0.940 1.042

0.0470 0.0423

0.0143 0.0129

0.0481 0.0434

0.0147 0.0132

0.0770 0.0695

0.0235 0.0212

FPN: The construction information is per NEMA WC8-1992 or ANSI/UL 1581-1998. The resistance is calculated per National Bureau of Standards Handbook 100, dated 1966, and Handbook 109, dated 1972.

70–625 TABLES NATIONAL ELECTRICAL CODE, 2002 Edition

16* 21* 28 38 51 59 69 80 94 108 124 147 160 185 202 218 254 279 310 321 331 350 382

18* 25* 33 45 61 70 83 95 113 129 147 176 192 221 242 261 303 335 371 384 397 421 460

21* 28* 37 51 69 79 93 106 127 146 167 197 217 250 273 295 342 378 420 435 450 477 521

1.08 1.00 0.91 0.82 0.71 0.58 0.41 — — —

1.05 1.00 0.94 0.88 0.82 0.75 0.67 0.58 0.33 —

1.04 1.00 0.96 0.91 0.87 0.82 0.76 0.71 0.58 0.41

1.08 1.00 0.91 0.82 0.71 0.58 0.41 — — —

1.05 1.00 0.94 0.88 0.82 0.75 0.67 0.58 0.33 —

1.04 1.00 0.96 0.91 0.87 0.82 0.76 0.71 0.58 0.41

For ambient temperatures other than 30°C (86°F), multiply the ampacities shown above by the appropriate factor shown below.

Correction Factors

21* 27* 36* 48 65 89 102 119 137 163 186 214 253 276 317 345 371 427 468 514 529 543 570 617

Types THHN, THHW, THW-2, THWN-2, RHH, RWH-2, USE-2, XHHW, XHHW-2, ZW-2

90°C (194°F)

70–77 79–86 88–95 97–104 106–113 115–122 124–131 133–140 142–158 160–176

Ambient Temp. (°F)

14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000

Size (AWG or kcmil)

SOURCE: NEC2002

*Unless otherwise specifically permitted elsewhere in this Code, the overcurrent protection for these conductor types shall not exceed 15 amperes for 14 AWG, 20 amperes for 12 AWG, and 30 amperes for 10 AWG copper; or 15 amperes for 12 AWG and 25 amperes for 10 AWG aluminum and copper-clad aluminum.

21–25 26–30 31–35 36–40 41–45 46–50 51–55 56–60 61–70 71–80

Ambient Temp. (°C)

18* 24* 33* 43 58 79 90 105 121 145 166 189 223 245 281 305 328 378 413 452 466 479 500 542

16* 20* 27* 36 48 66 76 88 102 121 138 158 187 205 234 255 274 315 343 376 387 397 415 448

14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000

Types TW, UF

Types RHW, THHW, THW, THWN, XHHW

75°C (167°F)

ALUMINUM OR COPPER-CLAD ALUMINUM

Types RHW, THHW, THW, THWN, XHHW, ZW COPPER

TypeTW

Types THHN, THHW, THW-2, THWN-2, RHH, RWH-2, USE-2, XHHN, XHHW-2, ZW-2

Size (AWG or kcmil)

60°C (140°F)

90°C (194°F)

75°C (167°F)

60°C (140°F)

Temperature Rating of Conductor. (See Table 310.13.)

Table B.310.1 Ampacities of Two or Three Insulated Conductors, Rated 0 Through 2000 Volts, Within an Overall Covering (Multiconductor Cable), in Raceway in Free Air Based on Ambient Air Temperature of 30°C (86°F)

17

14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000 14 12 10 8 14 12 10 8

4 3 2 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 8 6 5 2 6 4 3 1

16 (d)

SOURCE: NEC2002

TW, THHW, THW, THW-2 RHH*, RHW*, RHW-2*,

RHH, RHW, RHW-2

Type

Size (AWG/kcmil)

Conductor

7 6 5 2 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 15 11 8 5 10 8 6 4

21 (f)

11 9 8 4 3 2 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 25 19 14 8 6 13 10 6

27 (1)

20 17 13 7 5 4 4 3 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 43 33 24 13 28 23 18 10

35 (1b)

27 23 18 9 8 6 5 4 3 2 2 1 1 1 1 1 1 1 1 0 0 0 0 0 58 45 33 18 39 31 24 14

41 (1d)

46 38 30 16 13 10 9 7 5 4 4 3 3 1 1 1 1 1 1 1 1 1 1 1 96 74 55 30 64 51 40 24

53 (2)

80 66 53 28 22 17 15 13 9 7 6 5 5 3 3 3 2 2 1 1 1 1 1 1 168 129 96 53 112 90 70 42

63 (2d)

Metric Designator (Trade Size)

CONDUCTORS

120 100 81 42 34 26 23 20 13 11 10 8 7 5 5 4 4 3 3 2 2 2 1 1 254 195 145 81 169 136 106 63

78 (3)

157 131 105 55 44 34 30 26 17 15 13 11 9 7 6 6 5 4 4 3 3 3 3 2 332 255 190 105 221 177 138 83

91 (3d)

201 167 135 70 56 44 38 33 22 19 17 14 12 9 8 7 7 6 5 4 4 4 3 3 424 326 243 135 282 227 177 106

103 (4)

Table C1 Maximum Number of Conductors or Fixture Wires in Electrical Metallic Tubing (EMT) (Based on Table 1, Chapter 9)

Conduit and Tubing Fill Tables for Conductors and Fixture Wires of the Same Size

18

6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000

1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 12 9 5 3 2 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0

16 (d)

SOURCE: NEC2002

THHN, THWN, THWN-2

RHH*, RHW*, RHW-2*, TW, THW, THHW, THW-2

Type

Size (AWG/kcmil)

Conductor

3 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 22 16 10 6 4 2 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0

21 (f)

4 3 3 2 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 35 26 16 9 7 4 3 3 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0

27 (1)

8 6 5 4 3 2 1 1 1 1 1 1 1 1 1 0 0 0 0 0 61 45 28 16 12 7 6 5 4 3 2 1 1 1 1 1 1 1 1 1 0 0 0 0

35 (1b)

11 8 7 6 4 3 3 2 1 1 1 1 1 1 1 1 1 1 0 0 84 61 38 22 16 10 8 7 5 4 3 3 2 1 1 1 1 1 1 1 1 1 1 1

41 (1d)

63 (2d)

18 32 13 24 12 20 10 17 7 12 6 10 5 9 4 7 3 6 3 5 2 4 1 4 1 3 1 3 1 2 1 1 1 1 1 1 1 1 1 1 138 241 101 176 63 111 36 64 26 46 16 28 13 24 11 20 8 15 7 12 6 10 5 8 4 7 3 6 3 5 2 4 1 4 1 3 1 2 1 2 1 1 1 1 1 1 1 1

53 (2)

Metric Designator (Trade Size)

CONDUCTORS

Table C1 (Continued)

48 36 31 26 18 16 13 11 9 7 6 6 5 4 3 3 3 3 2 2 364 266 167 96 69 43 36 30 22 19 16 13 11 9 7 6 6 5 4 3 3 3 3 2

78 (3)

63 47 40 34 24 20 17 15 12 10 8 7 7 6 4 4 4 3 3 3 476 347 219 126 91 56 47 40 29 25 20 17 14 11 10 9 8 6 5 4 4 4 3 3

91 (3d)

Conduit and Tubing Fill Tables for Conductors and Fixture Wires of the Same Size

81 60 52 44 31 26 22 19 16 13 11 10 9 7 6 5 5 5 4 4 608 443 279 161 116 71 60 51 37 32 26 22 18 15 13 11 10 8 7 6 5 5 4 4

103 (4)

19

4 4 3 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 10 7 5 3 6

5 4 2

1 1

14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000 1250 1500 1750 2000 14 12 10 8 14

12 10 8

6 4

16 (d)

SOURCE: NEC2002

TW, THHW, THW, THW-2 RHH*, RHW*, RHW-2 RHH*, RHW*, RHW-2* RHH*, RHW*, RHW-2* RHH*, RHW*, RHW-2*,

RHH, RHW, RHW-2 RHH, RHW, RHW-2

Type

Size (AWG/kcmil)

Conductor

2

3

7 4

9

6 5 3 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 17 13 9 5 11

8

21 (f)

4

5

11 7

14

11 8 4 3 3 2 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 27 21 15 8 18

13

27 (1)

6

9

19 12

25

18 15 8 6 5 4 3 2 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 47 36 27 15 31

22

35 (1b)

9

12

26 16

34

25 20 10 8 6 6 5 3 3 2 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 64 49 36 20 42

30

41 (1d)

70

63 (2d)

15

20

43 26

56

21

28

61 37

79

41 58 33 47 17 24 14 19 11 15 9 13 8 11 5 7 4 6 4 6 3 5 3 4 1 3 1 3 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 1 0 1 0 1 104 147 80 113 59 84 33 47 69 98

49

53 (2)

Metric Designator (Trade Size)

CONDUCTORS

32

43

95 57

122

89 72 38 30 23 21 18 12 10 9 7 6 5 4 4 3 3 2 2 1 1 1 1 1 1 1 1 228 175 130 72 151

108

78 (3)

43

58

127 76

163

120 97 50 40 31 28 24 16 14 12 10 9 6 6 5 5 4 3 3 3 3 2 2 1 1 1 1 304 234 174 97 202

144

91 (3d)

56

75

163 98

209

154 124 65 52 41 36 31 20 18 15 13 11 8 7 7 6 5 4 4 4 3 3 3 2 1 1 1 392 301 224 124 261

186

103 (4)

Table C4 Maximum Number of Conductors or Fixture Wires in Intermediate Metal Conduit (IMC) (Based on Table 1, Chapter 9)

20

3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000

1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 14 10 6 3 2 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0

1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 24 17 11 6 4 3 2 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0

21 (f)

3 3 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 39 29 18 10 7 4 4 3 2 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0

27 (1)

6 5 3 3 2 1 1 1 1 1 1 1 1 0 0 0 0 0 68 49 31 18 13 8 6 5 4 3 3 2 1 1 1 1 1 1 1 1 1 0 0 0

35 (1b)

8 6 4 4 3 3 2 1 1 1 1 1 1 1 1 1 1 0 91 67 42 24 17 10 9 7 5 4 4 3 2 1 1 1 1 1 1 1 1 1 1 1

41 (1d)

63 (2d)

13 18 11 15 7 11 6 9 5 8 4 6 4 5 3 4 2 4 2 3 1 3 1 2 1 1 1 1 1 1 1 1 1 1 1 1 149 211 109 154 68 97 39 56 28 40 17 25 15 21 12 17 9 13 8 11 6 9 5 7 4 6 3 5 3 4 2 4 2 3 1 3 1 2 1 1 1 1 1 1 1 1 1 1

53 (2)

Metric Designator (Trade Size)

CONDUCTORS

28 23 16 14 12 10 8 7 6 5 4 4 3 3 2 2 2 1 326 238 150 86 62 38 32 27 20 17 14 12 9 8 7 6 5 4 3 3 3 3 2 2

78 (3)

37 31 22 19 16 13 11 9 8 7 6 5 4 4 3 3 3 3 436 318 200 115 83 51 43 36 27 23 19 16 13 10 9 8 7 6 5 4 4 4 3 3

91 (3d)

48 41 28 24 20 17 14 12 10 9 8 7 5 5 4 4 4 3 562 410 258 149 107 66 56 47 35 29 24 20 17 13 12 10 9 7 6 5 5 5 4 4

103 (4)

SOURCE: NEC2002

Note: This table is for concentric stranded conductors only. For compact stranded conductors, Table C4(A) should be used. *Types RHH, RHW, and RHW-2 without outer covering.

THHN, THWN, THWN-2

TW, THW, THHW, THW-2

Type

Size 16 (AWG/kcmil) (d)

Conductor

Table C4 (Continued)

21

4 3 3 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 9 7 5 3 6

5 3 1

1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000 14 12 10 8 14

12 10 8

6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000

SOURCE: NEC2002

RHH*, RHW*, RHW-2* RHH*, RHW*, RHW-2* RHH*, RHW*, RHW-2* RHH*, RHW*, RHW-2*, TW, THW, THHW, THW-2

TW, THHW, THW, THW-2

RHH, RHW, RHW-2

Type

12 10 8 4 3 2 2 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 25 19

21 17 14 7 6 4 4 3 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 44 33

3 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0

6 4

8

5 3 3 2 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0

8 6 5 4 3 2 2 1 1 1 1 1 1 1 1 0 0 0 0 0

10 18 6 11

13 23

11 8 7 6 4 3 3 2 1 1 1 1 1 1 1 1 1 1 1 0

25 15

32

34 19 39

28 23 19 10 8 6 5 4 3 2 2 1 1 1 1 1 1 1 1 1 0 0 0 0 59 45

27 35 41 (1) (1b) (1d)

18 14 12 10 7 6 5 4 3 3 2 1 1 1 1 1 1 1 1 1

41 24

52

56 31 65

176 146 118 61 49 38 34 29 19 17 14 12 11 8 7 6 6 5 4 4 3 3 3 3 370 284

276 229 185 97 77 60 53 46 30 26 23 20 17 13 11 10 9 8 6 6 5 5 5 4 581 446

103 129 (4) (5)

398 330 267 139 112 87 76 66 44 38 33 28 24 18 16 15 13 11 9 8 8 7 7 6 839 644

155 (6)

27 20 17 14 10 8 7 6 5 4 3 3 3 2 1 1 1 1 1 1

41 31 26 22 15 13 11 9 8 6 5 5 4 3 3 2 2 2 1 1

55 41 35 30 21 18 15 13 10 8 7 6 6 5 4 3 3 3 3 2

71 53 45 38 27 23 19 16 14 11 9 8 7 6 5 4 4 4 4 3

111 83 71 60 42 36 31 26 21 17 15 13 12 10 8 7 7 6 6 5

160 120 103 87 61 52 44 37 31 25 22 19 17 14 12 10 10 9 8 8

58 90 120 154 242 350 35 54 72 92 145 209

75 115 154 198 311 448

80 123 164 212 332 480 44 68 91 118 185 267 93 143 191 246 387 558

136 113 91 48 38 30 26 23 15 13 11 10 8 6 5 5 4 4 3 3 3 2 2 1 288 221

63 78 91 (2d) (3) (3d)

46 66 102 38 55 85 31 44 68 16 23 36 13 18 29 10 14 22 9 12 19 7 11 17 5 7 11 4 6 10 4 5 8 3 4 7 3 4 6 1 3 4 1 2 4 1 2 4 1 1 3 1 1 3 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 98 140 216 75 107 165

53 (2)

Metric Designator (Trade Size)

CONDUCTORS

9 14 25 5 8 14 10 17 29

7 6 5 2 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 15 12

Size 16 21 (AWG/kcmil) (d) (f)

Conductor

Table C8 Maximum Number of Conductors or Fixture Wires in Rigid Metal Conduit (RMC) (Based on Table 1, Chapter 9)

22

14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000

13 22 36 63 9 16 26 46 6 10 17 29 3 6 9 16 2 4 7 12 1 2 4 7 1 1 3 6 1 1 3 5 1 1 1 4 1 1 1 3 0 1 1 2 0 1 1 1 0 1 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 0 1 0 0 0 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

53 (2)

63 78 91 (2d) (3) (3d)

103 129 (4) (5)

155 (6)

85 140 200 309 412 531 833 1202 62 102 146 225 301 387 608 877 39 64 92 142 189 244 383 552 22 37 53 82 109 140 221 318 16 27 38 59 79 101 159 230 10 16 23 36 48 62 98 141 8 14 20 31 41 53 83 120 7 11 17 26 34 44 70 100 5 8 12 19 25 33 51 74 4 7 10 16 21 27 43 63 3 6 8 13 18 23 36 52 3 5 7 11 15 19 30 43 2 4 6 9 12 16 25 36 1 3 5 7 10 13 20 29 1 3 4 6 8 11 17 25 1 2 3 5 7 10 15 22 1 2 3 5 7 8 13 20 1 1 2 4 5 7 11 16 1 1 1 3 4 6 9 13 1 1 1 3 4 5 8 11 1 1 1 3 4 5 7 11 1 1 1 2 3 4 7 10 1 1 1 2 3 4 6 9 1 1 1 1 3 4 6 8

27 35 41 (1) (1b) (1d)

Metric Designator (Trade Size)

CONDUCTORS

295,950

236,760

591,900 789,200 789,200 986,500 986,500 1,243,000 1,578,400 1,973,000

300 400 400 500 500 630 800 1000

473,500

300

150

500

250

120

187,500

240

3/0

95

187,500

138,110

365,000

3/0

98,650

69,055

49,325

49,325

31,558

31,558

185

2/0 95

2

25

70

2

25

1

6

16

1/0

6

16

50

8

10

35

19,730

8

10

19,730

Circ Mils

Wire Size MM AWG

127

127

127

91

61

91

61

61

61

61

37

37

37

19

19

19

19

19

7

7

1

7

1

# of Strands

Metric Conductors

SOURCE: NEC2002

3.20

2.85

2.52

2.65

3.20

2.36

2.85

2.52

2.25

2.52

2.25

2.03

1.78

2.52

2.14

1.78

1.53

1.35

2.14

1.70

4.50

1.35

3.57

Strand Diameter

41.60

37.05

32.76

29.15

28.80

25.96

25.65

22.68

20.25

17.64

15.75

14.21

12.46

12.60

10.70

8.90

7.65

6.75

6.42

5.10

4.50

4.05

3.57

Black

Pink

Green

Brown

Gray

Blue

Blue

Red

Red

Color Code

1.638

1.459

1.290

1.148

1.134

1.022

1.000

0.893

0.797

0.695

0.620

0.560

Black

Black

Green

Brown

Red

White

Purple

0.490 Orange

0.496 Orange

0.421

0.350

0.300

0.266

0.253

0.200

0.177

0.159

0.140

Diameter Diameter MM Inch

125

106

106

94

87

71

66

54

50

50

45

42

37

33

29

24

24

21

21

Die Code

Note: This table is for concentric stranded conductors only. For compact stranded conductors, Table C8(A) should be used. *Types RHH, RHW, and RHW-2 without outer covering.

THHN, THWN, THWN-2

Type

Size 16 21 (AWG/kcmil) (d) (f)

Conductor

Table C8 (Continued)

23

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