If you don't know how to test and fix fault conditions as you have described you should not be doing what you are doing. Any work on a circuit carrying 480 Volts is potentially very dangerous. Unless you are a licensed electrician don't even attempt it!
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As always, if you are in doubt about what to do, the best advice anyone should give you is to call a licensed electrician to advise what work is needed.
Before you do any work yourself,
on electrical circuits, equipment or appliances,
always use a test meter to ensure the circuit is, in fact, de-energized.
IF YOU ARE NOT ALREADY SURE YOU CAN DO THIS JOB
SAFELY AND COMPETENTLY
REFER THIS WORK TO QUALIFIED PROFESSIONALS.
Yes. The thing that has to be closely watched is the load on the conductors. The conductors will have to be de-rated as the code only gives amperage rating for three conductors in a raceway. So watch the connected amperage to each load and fill the conduit accordingly. This supersedes the conduit fill requirements rule.
High voltage tests are done usually at the request of electrical engineers. When conductors are pulled into a conduit system, it is supposed to be done very carefully. In some instances this can not be done with out subjecting the conductors to mechanical stress. A high voltage test is applied to these conductors to make sure that the insulation factor of the wire has not been compromised. If the conductors do not pass the test, they have to be removed and new wire reinstalled.
A 100 foot fish tape and wire lubrication will be needed to make this wire pull.
When installing surface mounted cable the best method of ensuring that it is kept straight is by using more fasteners that is required by the electrical code. Another way is to install it into a conduit chase. The conduit can be fastened to the building using a level to keep it straight. The cable can then be pulled into the conduit.
There are both industrial and home owner cable pulling techniques. The former may involve heavy equipment and cable greasing and many people. Pulling cable on a small scale involves a snake and sometimes a pull cord. A snake is a coiled metal strip that you push through the conduit. When it comes out the other end or to a pull box you connect the wire and pull it back through the conduit. If more wire might be pulled later, also attach a pull cord so it will be left behind in the conduit for future use.
Conduit is sized by the number of conductors that are being pulled into it. The conduit size of 1/2" will allow one #4 wire to be pulled into it. 3/4" will allow 2 and 1" will allow 4 #4 conductors to be pulled into it.
Yes. The thing that has to be closely watched is the load on the conductors. The conductors will have to be de-rated as the code only gives amperage rating for three conductors in a raceway. So watch the connected amperage to each load and fill the conduit accordingly. This supersedes the conduit fill requirements rule.
No. The new electrical code change does not allow any flexible conduit to be used as a ground means. It is now required to have a green ground wire pulled into the conduit with the other conductors in the flexible conduit. This grounded bonding conductor is not counted as wire fill when calculating the size of the flexible conduit to use
If the conduit has reached its limit as to how many wires can be in it, there is only one course of action and that it to install another conduit parallel to the existing one. The electrical code book only allows a certain cross sectional filling of any conduit size. The rule is based on the dissipation of heat from the conductors in the circuits through the conduit walls. Once the wire fill has reached that figure no more wires should be pulled in because of insulation heating. Over time the heating of the insulation could lead to insulation breakdown and then short circuiting of the existing conductors that are in the same conduit.
If the existing conduit has not been intentionally or accidentally interrupted it is still an adequate ground. If you are in doubt about this or if a test proves that it is not grounded, new conductors including a new ground wire can be pulled inside the conduit. If the existing conduit is flexible conduit and it has "jake" type twist connectors, rewiring with a ground is advisable as those type of connectors do not maintain a good ground connection.
A conduit bushing is used when a conduit is terminated in a junction box or enclosure. Its purpose is to provide a smooth rounded surface so that when the wire is pulled into the conduit the insulation on the wire will not be damaged.
High voltage tests are done usually at the request of electrical engineers. When conductors are pulled into a conduit system, it is supposed to be done very carefully. In some instances this can not be done with out subjecting the conductors to mechanical stress. A high voltage test is applied to these conductors to make sure that the insulation factor of the wire has not been compromised. If the conductors do not pass the test, they have to be removed and new wire reinstalled.
The conductor can be pulled into conduit and then buried but it is not certified for direct earth burial.
The sizing of conduit systems that wire has to be pulled into is dependant on the physical size of the conductor being drawn into the conduit. The second governing factor is the conductor count of the specific conductor that is needed. A 500 MCM copper conductor with an insulation factor of 90 degrees C is rated at 430 amps. This is where the conductor count is need by the service, as to whether the service is single or three phase. In this specific case, the electrical code will allow both single and three phase installations to use the same size conduit. A maximum total of four 500 MCM conductors can be drawn into a 78 mm diameter conduit.
When you refer to a pull box you have to be talking about a conduit system. In a metallic system, no don't have to ground pull boxes. By the fact that it is a metallic system the conduit and associated boxes are already grounded by the connection to the distribution panel. In a PVC conduit system a ground wire has to be pulled so that the load device has a return ground wire to trip the breaker on a ground fault. Pull boxes in a PVC system don't have to be grounded just the last junction box at the load.
A 100 foot fish tape and wire lubrication will be needed to make this wire pull.
A tee joint in the electrical trade is a conduit fitting. It is used in conduit work where there needs to be a device connected into the main conduit run. An example of this is where a light switch needs to be installed into the conduit run. The main conduit run starts at the distribution panel and proceeds to a lighting fixture. On the way a switch is needed to operate the light fixture. In the main conduit run a tee fitting is installed so as to pick up the switch for the fixture. When the conduit system is complete the wire is then drawn in. The "hot" conductor is pulled to the tee fitting and then diverts to the switch box to pick up the switch and then back up the same conduit to the tee fitting and then on to the lighting fixture. Splices are not usually made in tee fittings.