1. Fundamentals of Load Calculation
Load calculation is the critical first step in electrical design. It determines the size of the service entrance conductors, the main breaker panel, and the transformer required to supply power to a building. The primary goal is to balance safety (preventing overloads and fires) with economic efficiency (avoiding vastly oversized equipment).
There are two types of loads to consider:
- Connected Load: The simple arithmetic sum of the nameplate ratings of every single electrical device in the building. If you turned on every light, plugged in every appliance, and ran every motor simultaneously, this would be the connected load. Sizing a service for this value is usually unnecessary and prohibitively expensive.
- Demand Load: The statistically adjusted load that accounts for "diversity." It is highly improbable that the oven, dryer, AC, water heater, toaster, and every light bulb will be active at the exact same moment. Codes like the NEC and IEC provide "Demand Factors" to reduce the connected load to a realistic peak value.
2. Global Voltage Standards & Phase Systems
Understanding your local voltage system is crucial for accurate amperage calculation ($Amps = Watts / Volts$).
North America (Split-Phase & Wye)
- Residential (120/240V): Homes receive two 120V "legs" and a neutral. Large appliances (dryers, ranges, AC) connect across both legs for 240V, while lights and outlets use one leg for 120V.
- Commercial (208Y/120V): A 3-phase system common in offices. It provides 208V for motors and 120V for outlets. Note that 208V is lower than residential 240V, meaning heaters will produce 25% less heat unless rated for 208V.
- Industrial (480Y/277V): Used for heavy machinery and commercial lighting. Lighting often runs on 277V.
Europe, Asia, Australia (IEC Standards)
- Residential (230V): Most homes receive a single phase of 230V (Line to Neutral). Unlike the US split-phase, all appliances run on this single voltage.
- Commercial/Industrial (400V/415V): A 3-phase system providing 400V (Line-to-Line) and 230V (Line-to-Neutral). This allows powerful motors to run efficiently while supplying standard office power.
3. NEC Article 220: The "Standard Method"
The National Electrical Code (NEC) Article 220 outlines the prescriptive method for calculation used in the US. Key sections include:
- 220.12 (General Lighting): Assigns a VA/sq ft value based on occupancy (e.g., 3 VA for homes, 3.5 VA for offices). This covers all general lights and convenience outlets.
- 220.52 (Small Appliance & Laundry): Specific to homes. Requires 1500 VA circuits for kitchens and laundry areas to handle high-draw devices like toasters and irons.
- 220.53 (Appliance Derating): If a home has 4 or more fixed appliances (disposal, water heater, etc.), you can apply a 75% demand factor, recognizing they likely won't all cycle on at once.
- 220.55 (Electric Ranges): Electric cooking allows for massive diversity. A 12kW range is calculated at only 8kW because elements cycle on and off to maintain temperature.
- 220.60 (Non-Coincident Loads): Sizing for the "worst case" scenario between heating and cooling. You don't need capacity for both simultaneously.
4. Commercial Considerations
Commercial calculations differ significantly from residential ones due to the nature of the loads.
Continuous Loads (NEC 215.2)
A continuous load is defined as a load expected to run for 3 hours or more (e.g., store lighting, server room cooling). The service conductors and overcurrent protection must be sized at 125% of the continuous load rating. This extra 25% buffer prevents the breaker from tripping thermally under long-duration load.
Kitchen Equipment (NEC 220.56)
Commercial kitchens are energy-intensive. However, fryers, ovens, and warmers are thermostatically controlled. The code allows aggressive demand factors:
- 3 Units: 90%
- 4 Units: 80%
- 5 Units: 70%
- 6+ Units: 65%
5. Three-Phase Math Explained
For 3-phase systems, calculation errors are common if the $\sqrt{3}$ factor is ignored. The relationship between Total Power (kVA) and Line Current (Amps) is:
For example, a 50 kVA load at 208V 3-phase draws 139 Amps. The same 50 kVA load at 240V 1-phase would draw 208 Amps. This efficiency is why 3-phase is standard for commercial buildings.