Grounding and Bonding an Outdoor Switchboard

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adalewhite

Master Electrician, Electrical Design, Veteran
Location
Georgia
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Licensed Electrician, Electrical Designer, A&E PM
Would love to hear some thoughts on this.

The Condition:
This is a recently completed existing installation with a 4000A Outdoor NEMA 3R switchboard fed by a pad-mount transformer, we’ll call this External-MSB. This switchboard is a manual transfer switch and has a CT Section, a 4000A Main Circuit Breaker connected to the Utility pad-mounted transformer, a 4000A Breaker connected to a cam-lock section for the connection of a temporary generator. There are (12)sets of (4)600kCMIL (AL) conductors from the transformer to the main.

There is a set of three 10’ ground rods driven 20’ apart and connected to the ground bus in the External-MSB with 1/0(CU) cadwelded to each ground rod. The ground bus is factory bonded to the neutral bus.

From External-MSB bus downstream of the Main and the Generator breaker there are (12) sets of (4)600kCMIL(AL),500kCMIL(AL);G each set feeding 4000A MLO Internal-MSB. NEC 2017 is the current code.

Questions:
Based on 250.66(A) are the #1/0(CU) to the three ground rods sufficient to meet code and not required to be sized by Table 250.66?

250.66(A) Connections to a Rod, Pipe, or Plate Electrode(s).
If the grounding electrode conductor or bonding jumper connected to a single or multiple rod, pipe, or plate electrode(s), or any combination thereof, as described in 250.52(A)(5) or (A)(7), does not extend on to other types of electrodes that require a larger size conductor, the grounding electrode conductor shall not be required to be larger than 6 AWG copper wire or 4 AWG aluminum wire.

Discussion:
Since the External-MSB Main is the service disconnect and is outdoors, the other electrodes described in 250.52(A)(5) or (A)(7) are not available.

The connection between External-MSB and Internal-MSB is a feeder by definition and has the 500kCMIL(AL) equipment grounding conductors. I do believe these will need to be re-pulled to comply with 250.122.
 
The connections to the ground rods are never required by code to exceed #6 AWG. However, the engineer can make them bigger if he wants to and that is also a requirement unless you are allowed by your contract to ignore the drawings.

IMO, the code requires each set of conductors to have an EGC sized according to T250.122. A 4000 AMP CB would thus require either a 500 MCM copper or 750 MCM Aluminum conductor.
 
I agree, the EGC needs to be the 750’s in T250.122
The drawings show the #1/0(CU) for the GEC to the ground rods. Unfortunately there are some holes in the documents through all the revisions.
The contractor had the option to upgrade to aluminum but unfortunately looks like they just increased the number of sets and not the EGC.
 
Are the undersized EGC by any chance run in a metallic raceway or cable tray? If so, you could just cut the ends off and use the raceway or cable tray as the EGC and call what used to be the EGC a spare conductor. That would appear to me to be code legal.
 
Unfortunately they are run in PVC underground. On the plus side they are in 4” conduits which is large enough for (4)600kCMIL(AL), 750kCMIL(AL)G. And they are 20’ from the building.
 
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