Section 2 Installation

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1 This sample chapter is for review purposes only. Copyright The Goodheart-Willcox Co., Inc. All rights reserved. Section 2 Installation 4 Chapter 4 Wiring Systems Chapter 5 Conductors Chapter 6 Boxes, Fittings, and Covers Chapter 7 Device Wiring Chapter 8 Overcurrent Protection Chapter 9 Grounding Chapter 10 The Service Entrance Wiring Systems Objectives Information in this chapter will enable you to: Know where to find codes and authorities for an installation. Recognize the marks of the most popular testing agencies. List the different conductor systems used in residential and light commercial wiring. Explain the basics of conduit bending. Become familiar with the many different types of raceway systems. National Electrical Code (NEC) Nationally recognized testing laboratory (NRTL) Offset bend Occupational Safety and Health Administration (OSHA) Raceways Rigid metal conduit (RMC) Rigid polyvinyl chloride conduit (PVC) Romex Saddle bend Service-entrance cable (SE) Shrink Stub bend Underground feeder and branch-circuit cable (UF) Underground service-entrance cable (USE) Wiring Wiring system Technical Terms Anti-short bushing Armor Armored cable (AC) Authority having jurisdiction (AHJ) Back-to-back bend Bonding strip Box offset BX Cable Conduit Electrical metallic tubing (EMT) Electrical nonmetallic tubing (ENT) Field bend Flexible metal conduit (FMC) Greenfield Intermediate metal conduit (IMC) Liquidtight flexible metal conduit (LFMC) Nonmetallic sheathed cable (NM) Electrical Codes and Safety Agencies There are many different methods of providing electricity to the occupants of a modern residence. You will learn about the various types of conductors, devices, and procedures available to use and those that cannot be used. Before selecting any of these systems, you should be aware of the agencies and codes that ensure the materials and procedures you use are safe and reliable. 71

2 72 Section 2 Installation Chapter 4 Wiring Systems 73 The National Electrical Code The most informative and authoritative body of information concerning electrical wiring installation in the United States, and perhaps the world, is the National Electrical Code (NEC). See Figure 4-1. It establishes a set of rules, regulations, and criteria for the installation of electrical equipment. Compliance with these methods will result in a safe installation. Web Site For a copy of the National Electrical Code, visit the Web site of the National Fire Protection Association or write to: NFPA Batterymarch Park Quincy, MA The NEC is drafted by a team of experts assembled for this purpose by the National Fire Protection Association (NFPA). This team is formally called the National Electrical Code committee. They revise and update the NEC every three years. It is imperative that anyone installing electrical wiring obtains and studies the NEC. Articles and sections of the NEC are referred to out this text. Although certain portions, tables, and examples are directly quoted from its text, there is so much useful information in the NEC that not having it available would be a tremendous hindrance. Code Alert Articles 90, 100, and 110 provide a necessary foundation to the remainder of the Code. Article 90 informs us of what is and is not covered in the NEC. Article 100 gives us the absolute essential defi nitions necessary in any conversation regarding electricity. Using inconsistent terms leads to confusion and misinterpretation. Article 110 is the road map of the Code. Here, we fi nd the general requirements for electrical installations and, along with Articles 90 and 100, a solid footing to fully understand the rest of the NEC. Figure 4-1. The National Electrical Code is the set of rules that most installations must follow. State and Local Codes Although the NEC, itself, has no legal basis, it is often made mandatory under local or state rulings. In such cases it becomes a legal document. The authority having jurisdiction (AHJ) is the person or group of people responsible for approving the equipment, materials, an installation, or a procedure. The NEC is not an AHJ, but the building commission of your municipality may be the AHJ and will probably use the NEC for most electrical installations. The phrase authority having jurisdiction is used instead of a specific title, such as electrical inspector or county building commission, because the approving systems vary. Code enforcement Almost every state, region, or locality has some sort of electrical code. Many use the NEC in whole or in part. Article 90.4 of the NEC grants full power to the local inspection authority to interpret and modify meanings and intentions of the NEC. Further, some communities add regulations beyond those outlined in the NEC. For these reasons, the local inspector should be consulted for a copy of the local codes. Failure to do so will probably result in violations and an inspection failure. Inspection, permits, and licensing In many areas, permits and licensing are required to do electrical work. In such areas, the National Electrical Code (NEC): The most informative and authoritative body of information concerning electrical wiring installation in the United States. authority having jurisdiction (AHJ): The person or group of people responsible for approving the equipment, materials, an installation, or a procedure. utility company requires that permits be obtained and the work be done by or under a licensed electrician before they will furnish power. Contact the electrical inspector or power company supervisor for information pertaining to permits and licensing. Equipment Testing Agencies There are many recognized testing agencies out the U.S. and Canada. Each of these agencies, known as a nationally recognized testing laboratory (NRTL) tests materials and equipment submitted to them by electrical material manufacturers. If the materials and equipment submitted measure up to the testing agencies expectations, the items are listed as suitable for electrical installation. In addition, the product will be labeled with a recognized mark to identify the testing agency that approved the product. See Figure 4-2. Almost all reputable manufacturers of electrical materials and equipment submit their products for testing. Products that are not listed should be avoided. In fact, it violates the NEC to use an unlisted product when there are listed ones available. The most widely known testing agencies are Underwriters Laboratories (UL), Canadian Standards Association (CSA), and Intertek Testing Services NA (formerly ETL). Products listed by these and other testing agencies are sure to be wellconstructed and safe. See Figure 4-3. Occupational Safety and Health Administration (OSHA) The Occupational Safety and Health Administration (OSHA) is the agency with the responsibility of creating and enforcing health and safety standards to protect persons in all Web Site This Web site contains electrical-related OSHA standards, hazards information, and news. Underwriters Laboratories Intertek Testing Services NA (Formerly ETL) Canadian Standards Association Figure 4-2. These are a few of the marks that indicate approval by an NRTL. occupations within the U.S. OSHA is an agency within the United States Department of Labor. The regulations can be obtained by contacting the Office of Information Services, OSHA, U.S. Department of Labor, Washington, D.C. These safety regulations are often more detailed than those of the NEC and, in some instances, supercede the NEC rulings. When in doubt, consult the AHJ. nationally recognized testing laboratory (NRTL): A recognized testing agency that tests materials and equipment submitted to them by electrical material manufacturers to verify that the item is suitable for electrical installation. Occupational Safety and Health Administration (OSHA): An agency within the United States Department of Labor that is responsible for creating and enforcing health and safety standards to protect persons in all occupations within the U.S.

3 74 Section 2 Installation Chapter 4 Wiring Systems 75 Figure 4-3. Engineers test electrical appliances and equipment to ensure that the products are safe. (Underwriters Laboratories, Inc.) All persons involved in the electrical trade should become familiar with the OSHA electrical standards, which specifically address the following areas: Hazardous locations Wiring methods, components and equipment Special systems Specific purpose equipment Wiring design and protection Electric utilization systems Definitions General requirements History Brief OSHA Congress created OSHA under the Occupational Safety and Health Act, which was signed by President Richard M. Nixon. Since its inception in 1971, OSHA has helped to cut workplace fatalities by more than 60 percent and occupational injury and illness rates by 40 percent. Wiring Systems Conductors for carrying electricity are commonly called wiring. A wiring system includes the wire, its insulating cover, a protective cover, and connectors that fasten it to an electrical box. See Figure 4-4. In some systems, the protective covering and the wire are purchased separately and the electrician assembles them on the job. In other cases, the protective covering is installed during manufacture. Depending on the structure being wired, several different systems may be used. Regardless of the wiring system, it is important to have a continuous ground out every part of the system and every circuit. Refer to Chapter 9, Grounding of this text for grounding requirements. All of these systems are adequate for most installations. Some cannot be used where there are unusual hazards such as extreme moisture, explosive gases, or corrosive chemicals. The wiring system selected depends on: Type of dwelling (style) Materials and type of construction used (such as log, concrete, post and beam, or platform) wiring: The wires installed in a building that provide the electrical power out. wiring system: In residential construction, the materials and components used to deliver electricity from the service panel to electrical devices. The wiring system includes the wire, its insulating cover, a protective cover, and the connectors that fasten it to an electrical box. Surroundings of dwelling (hot, cold, wet, or dry) Cost of the electrical materials Contractor s preference Building code requirements Preference of owner (client) Power panel Wiring method (cable or conduit) Terminal box (for light fixture) Cables Armored Cable: Type AC Article AWG 1 AWG Receptacle box Junction box A cable is an arrangement of two or more conductors in a protective covering and is assembled by the manufacturer. The protective covering may be plastic, rubber, steel, or aluminum /2 Switch box Figure 4-4. Simple sketch of a wiring system. It is the part of the circuit that carries current from the source the boxes to a load. cable: An arrangement of two or more conductors in a protective covering assembled by the manufacturer.

4 76 Section 2 Installation Armored Cable Armored cable (AC) is a manufactured assembly of insulated conductors in a flexible interlocked metallic armor, Figure 4-5. AC is frequently called BX, a trade name for armored cable produced at the Sprague Electric division of General Electric. The conductors in AC may be copper, aluminum, or copper clad aluminum. The outer covering is called armor and is made of steel or aluminum. As always, see the manufacturer s instructions before installing. One of the conductors in the cable is an uninsulated conductor that is in continuous contact with the armor. This wire is called a bonding strip. The use of AC is generally limited to dry locations where it is not subject to physical damage. Thus, it may be used in masonry block, tile walls, attics, and wall spaces, as well as along studs, rafters, and joists. Also, care must be taken to maintain a bend radius of the AC that is five times its diameter. Armored cable is expressly forbidden for use in: Commercial garages. Hoistways, elevators, or cranes. Theaters or motion picture studios. AC is quite flexible and can be pulled bored holes with ease. The holes should be slightly larger than the cable to avoid strain during installation. AC can be measured and cut before it is pulled the holes in the framing members. Measure the distance along the route the cable will run and transfer this measurement to the cable. Allow 6 to 8 extra at each end for making connections. Cut the length of cable needed using a hacksaw, or reciprocating saw, Figure 4-6. Stripping armored cable There are several methods for cutting the metal armor and stripping the cable end. Regardless of the method used, always be careful to not damage the wires inside the armor. Hacksaw. The most common tool for cutting the armor is the hacksaw. The hacksaw blade is placed on the armor so that it makes a diagonal cut across one of the high ridges. See Figure 4-7. Once the armor is cuta, it can be twisted off the inside wires. Chapter 4 Wiring Systems 77 Cable cutter Hacksaw Reciprocating saw Figure 4-6. A hacksaw, reciprocating saw, or special cable cutter will cut AC. White wire covered with paper Anti-short bushing Paper Armor Black wire Bonding strip Figure 4-5. These are the components that make up armored cable. armored cable (AC): An assembly of insulated wires contained within a flexible metallic armor for protection. BX: Another name for armored cable (AC). BX is a trade name attributed to the Sprague Electric division of General Electric. armor: The metallic spiral tubing that protects the conductors in armored cable. bonding strip: A piece of wire manufactured into AC that runs the length of the armor and is in constant contact with it. It provides the continuous ground necessary in a bonded system. Figure 4-7. A hacksaw can be used to notch AC for stripping the armor.

5 78 Section 2 Installation Chapter 4 Wiring Systems 79 Aviation or tin snips. The first step is to bend the cable sharply where the armor will be cut. This will cause the interlocked armor to disengage. Twist the armor to force it to expand and expose one twist in the armor. Place one jaw of the snips under this exposed section and cut the armor. Remove the armor and trim any sharp corners. See Figure 4-8. Roto-Split. The specific directions will come with the tool when you purchase it, but here are the basic steps. First, place the cable into the channel of the tool. Squeeze the handle to hold the cable in place. Turn the crank until the pressure decreases. Remove the cable from the tool and rotate the armor until it breaks free. See Figure 4-9. After you have stripped the armor from the cable, you must install an anti-short bushing. This red, split, plastic sleeve is placed between the wires and the rough edge of the armor. Make sure to place the split of the bushing opposite the armor end for maximum protection. See Figure This bushing keeps the insulation from rubbing against the sharp edge of the armor. The bushing must be in place to pass an electrical inspection. Purchase plenty of bushings when buying armored cable. When the anti-short bushing is in place, bend the bonding strip back over the bushing and wrap the cable as shown. Add the connector and tighten the setscrew or the clamp. The setscrew type of connector cannot be used on aluminum AC. See Figure Code Alert Section Construction. Type AC cable shall have an armor of fl exible metal tape and shall have an internal bonding strip of copper or aluminum in intimate contact with the armor for its entire length. Rotate handle Cutter wheel Squeeze the lever to hold the AC in place Figure 4-9. A Roto-Split is a tool that slices the armor so that it can be twisted off the cable. (Seatek Co. Inc.) Bonding strip Bend the cable sharply to buckle it. Twist against the direction of the spiral. Cut the armor and trim off sharp edges. Paper is removed after bushing is installed Figure 4-8. Snips may be used to strip the armor from AC. End of armor anti-short bushing: A red, split, plastic sleeve placed between the wires and the rough edge of the armor in AC. Red anti-short bushing Figure Always install an anti-short bushing to protect the wires. The tab on the bushing helps the inspector see that it is installed.

6 80 Section 2 Installation Chapter 4 Wiring Systems 81 Setscrew type of connector cannot be used on aluminum-armored cable Steel AC Inspection tab of anti-short bushing is exposed Clamp type of connector (2 screws) Figure The setscrew connector cannot be used on aluminum AC. The clamping connector can be used on steel or aluminum AC. Always read the cable manufacturer s installation instructions for any restrictions. Jacket Grounded Ungrounded Grounding Ungrounded Figure This is typical nonmetallic sheathed cable with two current-carrying conductors, a grounded conductor, and a grounding conductor. Code Alert Section At least 6 of free conductor, measured from the point in the box where it emerges from its raceway or cable sheath, shall be left at each outlet, junction, and switch point for splices or the connection of luminaires (fi xtures) or devices. Where the opening to an outlet, junction, or switch point is less than 8 in any dimension, each conductor shall be long enough to extend at least 3 outside the opening. Nonmetallic Sheathed Cable the jacket and pull it to the end of the cable. Use a knife to carefully cut the jacket completely off the cable. See Figure Nonmetallic sheathed cable (NM) has two or more insulated conductors wrapped in a strong plastic or braided outer sheath. Often included is a bare copper ground wire, Figure NM is the easiest and, in many areas, the most popular system to install. NM is easily cut to length with cable cutters. A cable ripper is used to split the outer jacket from the point where the wires will be exposed to the end of the cable. Place the cutting tooth in the center of the cable about 8 from the end. Squeeze the ripper closed to pierce History Brief Romex Type NM cable is referred to almost universally as Romex, regardless of which company makes the cable. Originally developed by General Cable in Rome, New York, in 1922, NM cable is now made by many different companies. Measure 8. Place the cable ripper over the cable and press the cutter into the jacket. Nonmetallic Sheathed Cable: Types NM, NMC, and NMS Article 334 Type NM: Normally Type NMC: Moist, damp, or corrosive Type NMS: Normally 14 AWG 2 AWG /2 nonmetallic sheathed cable (NM): A cable with 2 or more conductors and a ground all within an outer jacket, suitable for use in most residential installations except where conduit is required. NM is called Romex in the trade. Slide the ripper to the end of the cable. You should be able to peel the jacket off as shown. Use a knife to cut the jacket off the cable. Always cut away from your body. Figure Strip off about 8 of outer covering from NM cable with a special knife or a cable ripper as shown. Romex: The trade name for NM cable invented by General Cable. It has come into popular use when referring to any brand of NM cable.

7 82 Section 2 Installation Wet USE only: Underground Service-Entrance Cable: Types SE and USE Article 338 Service-Entrance Cable 14 AWG 2000 kcmil Service-entrance cable (SE) may be a single conductor or a multiconductor assembly with or without an overall covering. It is used to bring electricity into a customer s building from an overhead utility pole. Underground service-entrance cable (USE) is used to supply electricity underground. Stripping the insulation off the conductor is done with an electrician s knife. Cut into the insulation around the circumference of the cable, without nicking the conductor. Cut the insulation lengthwise from the first cut to the end of the cable. Now, peel off the insulation. Since the conductors in these cables must be large enough to handle the power requirements of an entire building, they may be stiff and difficult to work into position. A cable /2 bender is handy to create small-radius bends in the heavy cable. Underground Feeder and Branch-Circuit Cable Underground feeder and branch-circuit cable (UF) is a nonmetallic sheathed cable that is run underground between the service equipment and the final branch circuit overcurrent device. A typical installation would be a branch from the main service panel to a detached garage. Although the materials in UF are designed for underground use, the cutting and stripping procedure is exactly the same as standard NM cable. As with all underground cables and conduit, review the local codes for proper burial depth. Raceways Raceways are protective coverings installed on site and used to contain wires. Raceway materials are selected depending on the intended application. Wire size and ampacity, environment, installation conditions (new or remodel), building codes, and cost are all factors that will determine the selection of a raceway. Raceways consist of conduit, boxes, and fittings. Conduit is the tubing connecting the boxes together. The wires are pulled from box to box the conduit. Boxes can be used for either junctions to connect the wires or mounting devices such as lamp fixtures, Wet Chapter 4 Wiring Systems 83 switches, and outlet receptacles. Fittings are used to connect pieces of conduit together, and connectors are used to connect the conduit to the boxes. Electrical Metallic Tubing Electrical metallic tubing (EMT) is called thin-wall conduit. EMT is not designed to be threaded; therefore, it is connected lengthto-length or to electrical boxes with suitable compression or setscrew fittings. When installed correctly, EMT is used as an effective equipment grounding conductor. See Figure Electrical Metallic Tubing: Type EMT Article 358 1/ Underground Feeder and Branch-Circuit Cable: Type UF Article 340 Wet Corrosive Underground Direct Burial 14 AWG 4/0 AWG N/A Setscrew fitting (coupling) Connector Compression fitting (coupling) Coupling service-entrance cable (SE): The cable used to bring power from the utility pole to the customer s building. underground service-entrance cable (USE): Serviceentrance cable that is approved for direct burial in the ground. underground feeder and branch-circuit cable (UF): Similar to NM, this cable is suitable for direct burial in the ground. It is used for providing power to detached garages, yard lamps, and outbuildings. Figure These are various types of EMT fi ttings. Locknut for the connector

8 84 Section 2 Installation Chapter 4 Wiring Systems 85 Cutting conduit The first step when cutting conduit is to secure it in a vise. This will help you make straighter cuts and avoid broken blades. If a vise is not available, brace the conduit against a secure surface such as a wall stud or a sawhorse. A hacksaw is normally used to cut all types of conduit. A reciprocating saw outfitted with a metal-cutting blade is also used to cut conduit. Either saw should be fitted with a blade having 18 to 24 teeth per inch for a clean cut. See Figure A square cut can be made with a pipe cutter, although it creates a large burr. Apply a small amount of cutting oil where the cut will be made. Slip the cutter mouth over the conduit and adjust the cutter wheel until the tool is snug. Rotate the cutter around the conduit. If the tool is too difficult to rotate, the wheel is too tight. Adjust the cutter wheel until the tool is firm but not difficult to rotate. Continue to rotate the tool and tighten the cutter slightly after each turn until the conduit is completely cut. See Figure Reaming conduit The ends of a length of conduit must be smooth to prevent any damage to the wire s insulation. After cutting the conduit, use a reamer, round file, or a deburring tool to remove the burrs. See Figure Bending metallic conduit The purpose of bending conduit is to route it around corners and over obstructions. There are numerous special manufactured fittings available that could be used to achieve similar routing, but field bends are preferred. A field bend is a bend that is made on the construction site. This generally saves time and is far more economical than installing fittings. Most bends in EMT are made with a conduit bender. Always use the correct size bender for the conduit you are bending. This tool is designed to create a bend with the proper bend radius. The NEC lists the minimum radius of conduit bends in Chapter 9, Table 2. Typical bends include stub (also known as stub-up), back-to-back, offset, and saddle. The following sections will help you make these fundamental bends. Bending conduit is an important skill you can master with practice. Hacksaw Reciprocating saw Figure To cut EMT, secure it in a vise or hold it firmly and use a hacksaw, reciprocating saw, or a pipe cutter. A pipe reamer mounted in a brace will quickly remove any burrs. Insert the reamer into the conduit end and rotate the reamer. Burrs may be removed with metal files. Use a flat file to remove any burrs on the outside of the conduit. Slide a round file in and out at a slight angle while rotating the conduit. Tighten the pipe cutter until it is snug. Figure A pipe cutter can be used to cut conduit. Rotate the pipe cutter around the conduit. Repeat the first two steps until the conduit breaks. raceways: A system of conduit, boxes, and fittings which wires are pulled. conduit: Round hollow tubing that is metal or plastic, rigid or flexible, that is used to protect wires from physical damage. electrical metallic tubing (EMT): Conduit made of aluminum with relatively thin walls, also called thinwall conduit. The smaller sizes can be easily bent with a hand tool. A deburring tool designed for EMT is available. Insert the tool into the end of the conduit and rotate the tool. The deburring tool will work on 1/2, 3/4, and 1 trade size EMT. Figure The burr created by cutting must be removed, or it may damage the insulation when pulling wires the conduit.

9 86 Section 2 Installation Chapter 4 Wiring Systems 87 Stub Bend A stub bend is a 90 bend that usually brings a horizontal run of conduit up or down to an outlet box. Practicing this basic bend will help you become familiar with the conduit bender. 1. Measure the height of the total bend. This is typically from the bottom of the horizontal conduit to the bottom of an electrical box. 2. Take this distance and subtract the radius of the conduit bender. The resulting number is the distance to mark from the end of the conduit. 3. Place the conduit in the bender with this mark aligned to the bender s arrow. 4. Press down on the foot pedal of the bender (while guiding the handle to keep the bend perpendicular to the floor) until the stub is Use a torpedo level to confi rm that the stub is vertical. See Figure Back-to-Back Bend A back-to-back bend produces two 90 bends on a single length of conduit. After the bends are made, both ends of the conduit are pointing in the same direction. 1. Create the fi rst bend by following the stub bend procedure. 2. Mark the distance from the outside of the fi rst bend to the position where the outside of the second bend should be. 3. Place the conduit into the bender so that the star point is aligned with this mark. 4. Create the second bend. 5. Mark the conduit where the height of the second bend should be. 6. Cut the second bend at the mark. This is much more accurate than trying to control the height prior to bending, as you would while making a stub bend. See Figure Step 3 Apply pressure on the bender with your foot. Your hand should only guide the direction of the bend. Step 2 Align the star of the bender with the mark on the conduit. Step 1 The distance between the outside of both bends when completed will be 40. Measure this distance from the outside of the first bend and mark. Step 4 Stop bending the conduit when it reaches 90. Step 1 Subtract 5 from the total height of the stub bend. This will be a 10 stub. Step 2 Align the arrow of the bender with the mark on the conduit. Step 3 Apply pressure on the bender with your foot. Your hand should only guide the direction of the bend. Figure Make a stub bend with a conduit bender and check it with a torpedo level. Step 4 Stop bending the conduit when it reaches 90. Step 5 Verify the distance from the outside of both bends. Figure A back-to-back bend is two stub bends on the same length of conduit. field bend: A conduit bend that is made in the field (on the work site). stub bend: A 90 bend used to bring a usually horizontal run of conduit up into a device box. Also called a stub-up bend. back-to-back bend: Describes two 90 bends in the same piece of conduit, regardless of the distance between bends. Offset Bend The offset bend is used when the conduit must go around an obstruction or when the plane of the conduit must change slightly. Generally, offsets may be done at almost any angle, but shallow bends (those at smaller angles) reduce the force required to pull the wires the conduit. Deeper bends will bring the offset bend: Two bends of equal angle a short distance apart to allow a conduit run to clear an obstacle.

10 88 Section 2 Installation Chapter 4 Wiring Systems 89 offset closer to the obstruction, but will make it more difficult to pull the wires. See Figure Another important factor when bending conduit is shrink. Shrink is the amount of shortening in a length of conduit caused by adding one or more bends. See Figure The angle and the distance between the two bends in an offset will influence the amount of shrink. Fortunately, this amount has been calculated and is available in the offset bend table. If the offset bend is going to occur after the obstruction, shrink does not have to be added into the bend location. Regardless of whether you create the offset before or after an obstruction, the bends will be made on the side of the mark that points away from the obstruction. See Figure Review the following procedures and compare the steps for creating an offset bend before and after an obstruction. In all types of bends, the amount of shrink depends on the size of the conduit. Shrink varies with bend radius, and each size of conduit must be bent to the proper radius. Offset Bend before an Obstruction 1. Measure the height of the offset. 2. Measure the distance between the connection point and the offset. 3. Look at the offset bend chart to determine which angle you would like to use for the offset bends. 4. Look at the offset bend chart to determine the shrink and the distance between the bends. 5. Add the shrink amount to the distance you measured in step Place a mark on the conduit at this calculated distance. 7. Take the distance between bends found in step 4 and mark the conduit back from the fi rst mark. 8. Place the conduit bender handle on the fl oor and secure it in place with your foot. 9. Place the conduit in the bender so that the fi rst mark is aligned with the arrow. 10. Bend the conduit to the angle determined in step 3, being careful not to kink it. 11. Without removing the conduit from the bender, rotate the conduit 180 and slide it until the second mark is aligned with the arrow. 12. Bend the conduit to the angle determined in step 3, being careful not to kink it. Offset Bend after an Obstruction 1. Measure the height of the offset. 2. Measure the distance between the connection point and the offset. 3. Mark the conduit at this distance. 4. Look at the offset bend chart to determine which angle you would like to use for the offset bends. 5. Look at the offset bend chart to determine the distance between the bends. 6. Take the distance between the bends and mark the conduit forward from the first mark. 7. Place the conduit bender handle on the fl oor and secure it in place with your foot. 8. Place the conduit in the bender so that the fi rst mark is aligned with the arrow. 9. Bend the conduit to the angle determined in step 4, being careful not to kink it. 10. Without removing the conduit from the bender, rotate the conduit 180 and slide it until the second mark is aligned with the arrow. 11. Bend the conduit to the angle determined in step 4, being careful not to kink it. Pro Tip Keeping Bends Aligned When putting two bends in a piece of conduit, they must be in perfect alignment so the conduit will lay flat against the wall. If one bend veers to the left and the other veers to the right, the conduit will not lay flat. To maintain alignment, find a seam in the concrete or tile floor. Line up the first bend and the bender with the seam to keep the second bend properly aligned. shrink: The effective shortening of the overall length of a piece of conduit due to bending. Step 1 Measure the distance to the obstruction. Step 2 Measure the height of the obstruction. Step 3 Review the offset bend chart to determine the angle of the offset, the distance between bends, and the shrink. Step 4 Add the distance to the obstruction and the shrink. Mark this distance from the end of the conduit. Step 5 The next mark you will make is the distance between bends. Mark this measurement from the first mark back to the starting end of the conduit. Step 6 Place the conduit in the bender with the first mark aligned with the arrow. Step 7 Bend the conduit 45. Step 8 Without removing the conduit, slide and rotate it 180 so that the second mark is aligned with the arrow. Step 9 Bend the conduit 45. Step 10 Install. Figure An offset bend is used to route the conduit over an obstruction.

11 90 Section 2 Installation Chapter 4 Wiring Systems Figure How offset angles affect the shrink amount. Box Offset An offset that is used frequently is called a box offset. The box offset brings the conduit off the mounting surface so that it can fi t into a knockout hole of an electrical box. See Figure Place one mark 2 and another 8 away from the end of the conduit. 2.Place the conduit bender handle on the floor and secure it in place with your foot. 3. Place the conduit in the bender so that the 2 mark is aligned with the arrow. 4. Bend the conduit to a 5 angle. 5.Without removing the conduit from the bender, rotate the conduit 180 and slide it forward (away from you) until the second mark is aligned with the arrow. 6.Bend the conduit (now in the opposite direction) to a 5 angle. 9. Remove the conduit and fl ip it end-for-end Place it back in the bender with the second lateral mark closest to you. 10. Line up the second lateral mark with the arrow and bend to 22 1/2. Step 1 Mark the conduit at 2. Step 2 Mark the conduit at 8. Saddle Bend Start Since the bend will need to finish here, shrink must be considered Direction of installation Since the bend will start here, shrink does not have to be considered Figure If the offset is to occur before the obstruction, shrink will affect the location of the bend. When the offset occurs after the obstruction, shrink will not affect the location of the bend. Finish The saddle bend goes around an obstruction and, unlike the offset bend, returns to the same level after passing the obstruction. The most common saddle consists of one 45 center bend and two 22 1/2 lateral bends. See Figure Measure the height of the offset and the distance between the connection point and the offset. 2. For every 1 of obstruction height, move the center mark forward 3/16 (assuming 1/2 conduit is being used). Mark the conduit with this new center mark. 3. Lateral marks are placed 2 1/2 away from the center mark for every 1 of obstruction height. Place one mark on each side of the center mark. 4.Place the conduit bender handle on the floor and secure it in place with your foot. 5. Place the conduit in the bender so that the center mark is aligned with the rim notch (or the teardrop mark). 6. Bend the conduit to 45, being careful not to kink it. 7.Without removing the conduit from the bender, rotate the conduit 180 and slide it forward (slide the fi rst bend away from you) until the lateral mark closest to you is aligned with the arrow. 8. Bend the conduit to 22 1/2. Step 3 Place the 2 mark at the arrow, and bend the conduit 5. Step 5 Install. Step 4 Place the 8 mark at the arrow, and rotate the conduit 180, and bend it 5. Figure A box offset is used to bring the conduit away from the mounting surface so that it fits into a box. box offset: The small offset, or kick, needed in the end of a piece of conduit so it can enter a knockout in a junction box or a device box. saddle bend: Most commonly a bend made of three bends close together used when the conduit has to leave its surface to go over an obstruction then return to the same surface. There is also a four-bend saddle, which consists of two offsets back-to-back or a short distance apart.

12 92 Section 2 Installation Chapter 4 Wiring Systems 93 Step 1 Measure the height of the obstruction. This duct is 4 tall. Step 2 Measure the distance from the conduit to the obstruction. The distance from the center of the duct to the center of the coupling is 20. Electrical Nonmetallic Tubing: Type ENT Article 362 Wet Corrosive 1/ Step 3 Calculate the placement of the center mark. For every 1 of obstruction height, move the center mark forward 3/16. The center mark in this example is 20 3/4 from the end of the conduit. Step 4 Lateral marks are placed 2 1/2 away from the center mark for every 1 of obstruction height. Place one mark on each side of the center mark. This example requires the lateral marks to be 10 from the center mark. Step 5 Place the conduit bender handle on the floor and secure it in place with your foot. Place the conduit in the bender so that the center mark is aligned with the rim notch (or the teardrop mark). Bend the conduit to 45, being careful not to kink it. Step 6 Without removing the conduit from the bender, rotate the conduit 180 and slide it forward (slide the first bend away from you) until the lateral mark closest to you is aligned with the arrow. Bend the conduit to 22 1/2. Step 7 Remove the conduit and flip it end-for-end. Place it back in the bender with the second lateral mark closest to you. Line up the second lateral mark with the arrow and bend the conduit to 22 1/2. Figure The saddle bend consists of one 45 center bend and two 22 1/2 lateral bends. Electrical Nonmetallic Tubing A newer type of plastic corrugated raceway called electrical nonmetallic tubing (ENT) is now recognized for general use by the NEC under Article 362. It is flame retardant and is resistant to moisture and chemical atmospheres. ENT can be used in almost any building or dwelling regardless of height and can be concealed behind walls, above ceilings, or embedded in concrete. Being lightweight and flexible, ENT is easy to handle. The various connectors, couplings, and fittings are attached with snap-locks or plastic bonding cement. Installation varies and should be performed according to the manufacturer s instructions. See Figure There are some restrictions and limitations on the use of ENT: Not for hazardous material Cannot be left exposed, with some exceptions Not to be used as supportive means Not permitted for direct burial application Not for voltage exceeding 600 V History Brief Smurf ENT is referred to in the trade as smurf tube or simply smurf. The distinctive blue color found on most, but not all, ENT is the reason for this nickname. Smurfs were bright blue cartoon characters that were popular in the early 1980s. Electrical nonmetallic tubing (ENT) Connector Nonmetallic box Figure Electrical nonmetallic tubing is a corrugated plastic tube that is easy to handle and install. (Carlon, Lamson & Sessions) electrical nonmetallic tubing (ENT): Plastic corrugated tubing that provides a flexible conduit. Also called smurf because one type of ENT is a bright blue color, like the Smurf cartoon characters.

13 94 Section 2 Installation Chapter 4 Wiring Systems 95 Wet Corrosive Rigid Metal Conduit Rigid metal conduit (RMC) is galvanized and somewhat similar to water pipe. It is used for both indoor and outdoor applications. Inside and out, the conduit is smooth and can be cut, threaded, reamed, and bent as necessary for proper installation. To cut RMC with a pipe cutter, follow the cutting procedure demostrated in the previous EMT section RMC must be firmly connected to items such as electrical outlet boxes, and panels with a threaded locknut and bushing. This solid connection is necessary because the conduit itself serves as Rigid Metal Conduit: Type RMC Article 344 1/2 6 the equipment grounding conductor. Thus, a separate equipment grounding conductor is not required when using RMC. Fittings should maintain a continuous ground out the system. See Figure RMC nipples 3 10 Code Alert Section Where a conduit enters a box, fitting, or other enclosure, a bushing shall be provided to protect the wire from abrasion unless the design of the box, fitting, or enclosure is such as to afford equivalent protection. Conduit bodies Threading RMC 1.Clamp the conduit into a pipe vise. See Figure Place an appropriately sized pipe reamer inside the end of the conduit. 3.Rotate the reamer until all the burrs are removed from the inside of the conduit. 4. Remove any burrs from the outside of the conduit with a fi le. 5.Mount a threading die inside the head of a hand threader. (See manufacturer s instructions.) 6. Add cutting oil to the end of the conduit to ease the cutting and prevent tool wear. 7.Place the threading die squarely on the end of the conduit. 8.Rotate the hand threader while pressing its head toward the conduit. 9. The die will engage the conduit and start cutting threads. 10. Stop pushing the head and continue rotating the hand threader. Add cutting oil to the conduit after every few rotations. 11. When the end of the conduit is even with the back of the threader die, stop the rotations. 12. Reverse the direction of the hand threader to remove it from the conduit. 13. Clean off the threads with a rag and remove the conduit from the vise. Rigid PVC Conduit Rigid polyvinyl chloride conduit (PVC) is constructed of polyvinyl chloride (PVC), a tough, nonconductive plastic. PVC weighs much less than metal conduit and is designed to be used everywhere other types of conduit are used. There are many different fittings available to connect Manual pipe threader Powered threading machine Figure Putting threads on RMC requires some specialized tools. (Ridge Tool Co.) the PVC to metallic and nonmetallic boxes and conduit. See Figure PVC is only restricted in certain hazardous locations and where it could be physically damaged. Check with your authority having jurisdiction (AHJ) to see if local code permits its use. Do not use to support fixtures. Coupling Preformed bends Locknuts Bushing Figure Rigid metallic conduit is threaded so that it can be attached to fi ttings and couplings. rigid metal conduit (RMC): This is the original conduit, used before thin-wall and IMC. RMC, also called heavy-wall conduit, has thick walls and provides the greatest protection for the wires inside. Small sizes can be bent by hand with difficulty; larger sizes must be machine-bent. Wet Corrosive Rigid Polyvinyl Chloride Conduit: Type PVC Article 352 1/2 6 rigid polyvinyl chloride conduit (PVC): A conduit that is constructed of polyvinyl chloride (PVC), a tough, nonconductive plastic. 3 See Table (B)

14 96 Section 2 Installation Chapter 4 Wiring Systems 97 Step 1 Apply primer to the inside of the fitting. Intermediate Metal Conduit: Type IMC Article 342 Step 2 Apply primer to the outside of the conduit. Wet Corrosive 1/ Figure Numerous types of fi ttings, elbows, and mounting hardware facilitate the installation of rigid PVC conduit. (Kraloy Fittings) PVC is easily worked. It can be bent using special bending boxes with heating elements to warm the conduit. This allows it to be easily bent by hand, using a simple bending jig. Preformed bends may also be obtained. To connect the PVC and fittings, a special glue and primer are used. See Figure Attaching Fittings to PVC 1. Clean the inside of the fi tting and the end of the conduit with a rag. 2. -fi t the fi tting on the conduit to check the fi nal position. 3. Remove the fi tting. 4. Apply primer to the inside of the fi tting and the outside of the conduit. 5. Apply cement to the primed areas. 6. Push the conduit into the fi tting while turning the fi tting a quarter turn. 7. Look at the seam for a bead of glue to indicate a proper amount of cement. Step 3 Apply glue to the inside of the fitting. Step 4 Apply glue to the outside of the conduit. Step 5 Push the conduit into the fitting. Turn the conduit 1/4 turn to spread the glue evenly. Step 6 This is a cutaway view of the completed assembly. Pro Tip Intermediate Metal Conduit The internal diameter (ID) of IMC is larger than that of the equivalent trade size of RMC; therefore, there is more room for pulling wires and calculating conduit fi ll. Flexible Metal Conduit (Greenfield) Flexible metal conduit (FMC) is a spiralwrapped metal conduit similar to the outer armor in AC. See Figure FMC is often called Greenfield because it was invented by Harry Greenfield. FMC is routed and attached as if it was nonflexible conduit, but it has the advantage of bending without using tools. There are special couplings, locknuts, and bushings for attaching FMC. The wire is fished as with other conduit. Flexible Metal Conduit: Type FMC Article 348 1/2 4 Code Alert Section Where used to connect equipment where fl exibility is required after installation, an equipment grounding conductor shall be installed. Where fl exibility is not required after installation, FMC shall be permitted to be used as an equipment grounding conductor when installed in accordance with (5) /2 Note: NEC requires conduit run underground to be sealed at joints prior to entering building. Intermediate Metal Conduit Intermediate metal conduit (IMC) is permitted for use in all atmospheric conditions and in all types of occupancies. Like its counterpart Figure Follow these steps to make the PVC attachments watertight. rigid metal conduit, IMC is available in 10 lengths. Each length or part of a length must be properly connected and joined to other lengths or enclosures using the correct fittings. IMC is available with or without threads. Installation is the same as rigid metal conduit. intermediate metal conduit (IMC): Conduit with walls thicker than EMT but thinner than RMC. Has many advantages over RMC because it is lighter in weight and has more room inside for pulling wires. flexible metal conduit (FMC): Metal corrugated tubing that provides a flexible conduit. Greenfield: A common name for FMC. liquidtight flexible metal conduit (LFMC): This conduit is FMC with a waterproof outer coating and special fittings to maintain its watertight integrity. Figure Flexible metal conduit (Greenfi eld) is similar to armored cable without the wires.

15 98 Section 2 Installation Chapter 4 Wiring Systems 99 Frequently, FMC is used with EMT or rigid conduit. It is substituted where bends are needed. Instead of making complicated bends and angles in EMT or rigid conduit, a section of FMC can be inserted. There are special bushings, locknuts, and couplings to connect FMC to the other forms of conduit. There are also length limits as stated in the NEC. In residential installations, LFMC is typically used to connect a central air conditioner unit to a disconnect. See Figure Its extreme flexibility makes LFMC an optimum choice to connect machinery that is portable or may vibrate during normal operation. LFMC is also permitted as a service wiring method up to 6 in length. Use of LFMC requires use of some special fittings and connecting procedures. Surface Metal Raceways Article 386 Unrestricted Surface Nonmetallic Raceways Article 388 See manufacturer s installation instructions Liquidtight Flexible Metal Conduit Liquidtight flexible metal conduit (LFMC) is similar to FMC, but LFMC is covered with a continuous plastic sheath. This system is easy to install and can be used in most locations. Surface-Mount Raceways Surface-mount raceway is an assembly of two sections, a base and a cover, that is generally rectangular or a flattened oval. Sections are 10 long and range from 3/8 to 3 high and Liquidtight Flexible Metal Conduit: Type LFMC Article 350 Wet Direct burial (where listed and marked) 1/2 4 Figure This air conditioner is connected to the disconnect with LFMC /2 Unrestricted from 1/2 to 4 wide. Surface-mount raceway is constructed of steel, aluminum, or plastic. Surface-mount raceway is mounted on wall or ceiling surfaces only in dry locations and where it will not be subjected to physical damage. Elbows, connectors, couplings, and boxes are designed to be electrically and mechanically continuous and compatible. It is useful in existing facilities when appearance is important and new wiring cannot be pulled walls. Review Questions Write your answers on a separate sheet of paper. Do not write in this book. 1. Name five key factors that determine the wiring system used for a particular installation. 2. True or False? When wiring with rigid metal conduit, a grounding conductor is required. 3. When rigid conduit is cut, it is important that it be to remove any sharp burrs that could damage the during wire installation. 4. A must be added to rigid conduit to protect the wires that are pulled. 5. Intermediate metal conduit is commonly sold in which of the following lengths: A. 3 B. 6 C. 8 D. 10 E. 12 See manufacturer s installation instructions 6. A bend is used when the con-- duit has to turn 90. Flexible 7. metal conduit is also called. 8. LFMC stands for. Armored 9. cable is known as AC and. 10. List three places where armored cable cannot be used. 11. True or False? Electrical metallic tubing cannot be used as an equipment ground. 12. Which article of the NEC outlines rules regarding rigid metal conduit? 13. The following are types of nonmetallicsheathed cable: NM, NMC, NMS. Where is each used? 14. Which article of the NEC outlines rules regarding rigid nonmetallic conduit? Know the Code A copy of the NEC 2011 is required to answer these questions. 1. What is the title of Section ? 2. What does the informational note in Section state? 3. True or False? Underground feeder can be used as a service-entrance cable.

16 100 Section 2 Installation Filler Photo? This nonmetallic electrical box is large enough for the number of wires required. The electrician has carefully tucked the wires inside to protect them when the sheetrock is installed.

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