Feeder Loading and Thermal Limits

8 min · difficulty 4/10

A feeder is already carrying 520 A on conductor rated for 640 A. A developer wants to add a load that would draw another 90 A at the feeder’s coincident peak. Does it fit? Answer before you read on.

It fits, barely. The test is total coincident load against the conductor’s ampacity: 520 + 90 = 610 A against a 640 A rating, leaving 30 A of headroom. Ampacity is the current a conductor can carry continuously before it overheats. It is a thermal limit, set by how much heat the conductor can shed, and it is a hard ceiling that has nothing to do with voltage quality. A feeder can run out of thermal room or voltage room first, and you check the two separately.

The number that trips people up is the 90 A. A new subdivision might have 240 A of connected nameplate load, but its homes and appliances never all peak in the same hour. That is diversity: the coincidence factor is well below 1, so the group’s contribution to the feeder’s peak hour is far smaller than the sum of its parts. You add the diversified, coincident contribution to the feeder’s peak, not the raw connected nameplate. Add nameplate and you would reject a load that actually fits; ignore diversity the other way and you would approve one that does not.

Feeder ampacity gauge: 520 A existing + 90 A new load leaves 30 A of headroom A horizontal gauge scaled zero to 640 amps. A blue segment fills the first 520 amps for existing load. An orange segment stacks on top of it for 90 amps of proposed new load, reaching 610 amps. A dashed green segment covers the remaining 30 amps of headroom up to the gold 640 amp rated ampacity line. Labels read 520 A existing, plus 90 A new load, 610 A total, 30 A headroom, and rated ampacity 640 A. Feeder ampacity gauge Rated ampacity = 640 A +90 A new load 30 A headroom 520 A existing 0 80 160 240 320 400 480 560 640 610 A total Existing load (520 A) Proposed new load (90 A) Headroom (30 A)
520 A existing plus 90 A of new load leaves only 30 A of thermal headroom under the 640 A rated ampacity.

That 30 A margin is thinner than it looks. If the diversity assumption is wrong and the new load’s coincident draw is 120 A instead of 90, the feeder lands at 640 A, dead on the rating with no room left. This is why planners do not load a feeder to 100 percent of ampacity in the first place. Headroom is what lets an operator transfer load onto this feeder when a neighboring one is out, and ampacity itself shrinks as ambient temperature climbs, so a summer afternoon rating is lower than a nameplate value. The thermal limit is specific to the conductor and its conditions, not a single fixed number.

A load fits only when its coincident contribution, not its nameplate, still leaves the feeder below its ampacity with room to spare. A buyer sizing a service, an operator weighing a transfer, and an engineer approving an interconnection are all running the same check: diversified load in, thermal ceiling as the wall, and deliberate headroom in between.

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Question 1 of 3

A feeder conductor is rated 640 A and is already carrying 520 A at peak. A new load contributes 90 A at the feeder's coincident peak. How many amps of headroom are left after the addition?

Educational material only. This is not engineering, safety, or procurement advice. Confirm any value against manufacturer documentation and a licensed professional before specifying equipment.