box fill calc

Box fill is easy, right?
If I have a box with a duplex receptacle, two #14 wires landing on the receptacle, a #14 ground and a cable clamp, the total inches required is 12 cubic inches. Now I want to add to the calculation nine #10 THHN conductors passing through the box, no loop. These conductors are in a 3/4" EMT secured to the box by lock rings. The #10 conductors add an additional 2.5" X 9 = 22.5". Is the clamp size increased from 2 to 2.5? If so, the total cubic inches added to the first calculation is 23 cubic inches, now the total is 35.

Now the question is a bit harder. Suppose three of the #10 are green. Now we have four grounding wires "entering" the box, three of which pass straight through, making four green wires. Only one green, the largest, is required to be counted until the number of grounding conductors exceeds four. That leaves a clamp at 2.5, a receptacle at 4, two #14 wires at 4, one green at 2.5, six #10 passing through at 15. Total is now 28. the only difference between the 35 cubic inch calculation above and the 28 inches here is that I've said three of the wires are green.

Or do you still say nine conductors are still passing through and you'll add another half inch to the grounding wire size, making the calculation 35.5 inches. Now you have four grounding conductors entering a box and are you not counting all of them as grounding conductors.

The smart thing to do is cut, splice, pigtail and land all the green #10 wires in the box, that ends all confusion. Now the calculation comes out less than 30 cubic inches, over five inches less than if they pass through and I'll bet that box size doesn't work as well as you might hope

Or does the code intend, when it says "present in the box" or "entering the box" to really mean "utilized in the box" and passing through is just "passing through"?
 
Q1 The situation you describe is highly unusual, my interpretation would be the largest wire in the box going through the clamp, and not the largest wire in the box. But the NEC is clear -largest wire in the box.
Q2 I would say 28ci if the three green conductors are indeed GECs.
Q3 If you count the GECs as current carrying conductors the grounding wire size allowance defaults back to 14ga

The NEC keeps complicating box fill calculations and the language might need revision. If you read 314.16B1 the implication for termination is that of conductor connected to something other than another conductor. So what happens if a wire just ends in the box unused Is it counted?
 
So what happens if a wire just ends in the box unused Is it counted?
Not sure where or if it's in the code but I think a spare or unused wire still counts in fill and ccc's.so I would think it counts in box fill too.
I dont think it can defy physics. :cool: JMO.
 
Yes, we could use one #10 for a grounding wire for all four circuits, it's always been my habit to provide a grounding wire for each circuit.

The #10 conductors travel through the box continue on to three separate 240V single phase loads. There are six black and three green conductors passing through the box, two black and one green for each of the three loads.

What I thought was interesting was that the box size decreased by 7" when three of the #10 wires were green wires. If you cut and splice each #10 grounding conductor passing through the box, leaving at least 6" of conductor on the six green #10 wires after you've cut them, pigtail them, land in them in the box, the calculation is still over five cubic inches less. Oh boy, what a pain that could be.
 
Yes, we could use one #10 for a grounding wire for all four circuits, it's always been my habit to provide a grounding wire for each circuit.

The #10 conductors travel through the box continue on to three separate 240V single phase loads. There are six black and three green conductors passing through the box, two black and one green for each of the three loads.

What I thought was interesting was that the box size decreased by 7" when three of the #10 wires were green wires. If you cut and splice each #10 grounding conductor passing through the box, leaving at least 6" of conductor on the six green #10 wires after you've cut them, pigtail them, land in them in the box, the calculation is still over five cubic inches less. Oh boy, what a pain that could be.
Is this a real installation? If so what kind of box are you using that is that large and has internal cable clamps?
 
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