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Suppose the resistance of a ground rod or equivalent was as low as 1 ohm. Very hard to achieve in most parts of the country. #6 copper is 0.4 ohms per 1000 ft or 0.004 ohms for 10 ft. Either of these is relatively insignificant to 1 ohm. At 10,000 A the 10 ft length will have a drop of 40 V.
The fusing current for #6 copper from the ITT handbook is 668 A. There are many variables that determine fusing current so this is only an approximation. Any very large current is going to be time limited. Lightning in particular is the most likely source of a current of 10,000 A in the type of application being discussed here. Thus, it is reasonable to expect that there would be no fusing problem here because the 668 figure is going to be based on a much longer time period.
Now consider a 200 KVA transformer with an internal impedance of 0.008 ohms. 200 KVA at 240 V is 834 A and the nominal full load transformer drop is 7.2 V. Somehow, and I do not know how this fault could naturally occur, but suppose that we apply 240 to 1.0 + 0.008 + 0.004 ohms, then the maximum current is 240/1.012 or 237 A well below the steady state fusing current of 668 A. This 237 is mostly a result from the high resistance of most earth and the interface between ground and the earth.
None of thiese assumptions would indicate any fallacy in the code specification of #6.
My above calculations are assuming all resistive components. In all cases there is inductance and for very fast waveforms, such as lightning, the impedance will be higher than the DC resistance.
In reality #6 is probably overkill going to a normal ground rod for anything other than lightning. Probably many ground rod installations are in the 10 ohms or higher range. However, using the same cross section of copper and making it broad and flat reduces the inductive effect and is useful in reducing voltage drop from lightning currents. At 240 V the current thru 10 ohms is 24 A.
How do you create a fault in wiring that will produce a large current into the ground rod. My home pole transformer has its center tap connected to a ground rod at the pole, and there is a ground at my main panel to my copper water supply, effectively a very good ground rod. At the time the house was built there was no requirement for a separate ground rod at the house. My house ground rod is essentially 150 ft of 1.25" copper pipe. If we open the neutral between the pole and house and short one of the hot wires to the water pipe with an assumption of 10 ohms ground resistance, then the fault current is 12 A. What else can I easily do to get a high current? I would have to get a much higher voltage somehow.
Here is an interesting calculation. Assume a lightning bolt is 10,000 A and the resistance to ground is 10 ohms. This means that at this instant the ground rod rises to a potential of 100,000 V relative to some place down in or across the earth. Also means everything connected to the building wiring rises this much relative to whatever that reference is.
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