User: Travis C, Location: VA
Asked on: Tuesday, July 29, 2025 at 1:50 pm EDT
Answered on: Tuesday, July 29, 2025 at 1:56 pm EDT
Question: I have been asked to run a circuit that is part of our automatic transfer switch and emergency generator backup. This circuit will contain 6 IT switches that are plugged into 6 uninterrupted power supplies. Each of these UPS are rated at 9.2A maximum load and are suggested to be placed on a 15A breaker. Total load of this circuit would be 55.2A which would size my breaker at 60A for the circuit. My thought is to run 60A wire to the top of a disconnect for each of the six UPS. I would then fuse that disconnect with a 15A fuse. To continue the circuit from each disconnect, I would use one that had multi lugs on the line side. Unfortunately, there is around 250 feet of distance from the furthest UPS to the breaker panel which would require me to use 1/0 wire for the branch circuit. Is my plan the way to proceed, or should i split the load into multiple circuits? If you have any advice i'd love to hear it. Thanks.
You're on the right track in considering a split load, but let's break down the issues and explore some safer and more cost-effective alternatives. Your current plan, while technically workable, presents some challenges and potential code violations.
Problems with Your Current Plan
Over-Fused Tap
Tapping a 60A conductor with a 15A fuse at each UPS location is tricky and may violate NEC 240.21(B) regarding tap rules. Tap rules require that the tap conductors must not exceed 25' in length.
Cost
1/0 wire for a branch circuit supplying only 55.2A is very expensive and likely overkill.
Disconnect Size
A 60A disconnect with 15A fuses seems odd and inefficient.
Future Expansion
You're maxing out your current circuit. Any future UPS additions would require a complete circuit overhaul.
Recommended Alternatives1. Split into Multiple Circuits Two Circuits
A much better approach is to split the load into two or even three separate circuits.
Option A: Two 30A Circuits
Use two 30A breakers at the panel. Run #10 AWG copper wire (rated for 30A). Calculate your voltage drop. You might need to upsize to #8. At each UPS, use a 30A rated disconnect (fused at 15A) for each UPS
Option B: Three 20A Circuits
Use three 20A breakers at the panel. Run #12 AWG copper wire (rated for 20A). Calculate your voltage drop, 250' is a long way. You might need to upsize to #10. At each UPS, use a 20A rated disconnect (fused at 15A) for each UPS
2. Address Voltage Drop Calculate Voltage Drop
The long run of 250 feet is the primary concern. Use a voltage drop calculator to determine the appropriate wire size for each circuit option. Aim for less than 3% voltage drop at full load.
Voltage Drop Compensating UPS
Some UPS models have input voltage compensation features that can help mitigate voltage drop issues.
3. Proper Disconnect Sizing Fused Disconnects
The best practice is to use a fused disconnect sized appropriately for the UPS branch circuit (15A).
Combination Devices
Consider using combination power distribution blocks with integrated fusing or circuit breakers. These simplify the wiring and provide better overcurrent protection.
4. Code Compliance NEC Article 645 (Information Technology Equipment)
Since you're dealing with IT equipment, be aware of Article 645, especially regarding disconnect requirements and cabling methods. Consult with a licensed electrician to ensure full compliance.
Local Codes
Local electrical codes may have additional requirements.
Implementation Steps (for Split Circuit Options)
Calculate Load
Determine the actual load each UPS is expected to draw under normal operation. Don't just rely on the maximum rating.2.
Calculate Voltage Drop
Use an online calculator (search for "voltage drop calculator") to determine the appropriate wire size based on the load, distance, and acceptable voltage drop.3.
Select Breakers
Choose appropriately sized circuit breakers for each circuit (20A or 30A).4.
Run Wiring
Run the correct gauge wire from the panel to each UPS location, using approved wiring methods (conduit, cable tray, etc.).5.
Install Disconnects
Install a properly sized fused disconnect for each UPS.6.
Connect UPS
Connect each UPS to its dedicated fused disconnect.7.
Labeling
Clearly label all circuits and disconnects at the panel and at each UPS location.
Important Considerations
Licensed Electrician
It is highly recommended to consult with a qualified, licensed electrician for this project. They can perform load calculations, select appropriate equipment, and ensure code compliance.
Safety
Electrical work can be dangerous. Always de-energize circuits before working on them and follow all safety precautions.
Future Scalability: When designing the circuit, consider the possibility of adding more UPS units in the future. Leave some capacity on each circuit or run larger conduit to accommodate future wiring.By splitting the load into multiple circuits, using appropriate wire sizing, and ensuring proper overcurrent protection, you can create a safer, more efficient, and cost-effective solution for powering your IT equipment. Remember to always consult with a qualified electrician to ensure compliance with all applicable codes and regulations. Flag for review