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Melted 12-3 wiring

L8CS

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Hi everyone.

I have an existing Square D Homeline Subpanel in my garage that I run my Bosch 220V double oven from. I've had the oven since 2006 and ran it from a 15' length of 12-3 to the Garage Subpanel which is supplied by a 65' run of 6-3 from the Main Breaker. I've recently relocated the Subpanel closer to the oven and shorted the 12-3 down to 6'. The oven draws 31 amps and I've never had a problem until tonight. The 12-3 is also in Sch 40 from the wall to the panel.

The oven was warming up and suddenly popped the 30 amp double pole. In checking further, I found one side of the 12-3 melted approx. 2" and bubbled up just under the breaker. I also found the breaker set screw somewhat loose. I know a loose connection will arch but will a loose connection at the breaker overheat and melt the insulation back?

I had run a new circuit into it yesterday and could have jarred it loose but that's the only plausible explanation I can come up with. I'm going to pull the oven Saturday and replace the 12-3 with 10-3 because I can't trust it after the meltdown.

Any help would be appreciated.
 
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kingchevy

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12-3 on a 30 amp breaker supplying a 31 amp load, no surprise here other than it didn't happen sooner.
 

ddawg16

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Now you know why we have the NEC.

30A? You need 10 Awg wire....

I suspect the only reason you got by up to now is because of the voltage drop for the distance of your original run. With the shorter wires...current goes up...wire gets hotter......melts.

Actually....you really need 8 Awg wire and a 40A breaker....
 
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Richard Cranium

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I agree, to both, the loose connection added to the heat, plus shortening the run dropped the voltage drop, so the oven was getting more amps...thank god for breakers, You still have a garage and home....
 

walrus

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You need to read the data plate and size wire from that. Go online and find installation instruction for that oven
 
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L8CS

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Thanks for the help.

In my defense, I originally consulted the 37th edition of Wiring a Simplified written by H.P. Richter and based on the 1993 NEC. It stated that a #12 one way distance with a 2% drop at 240V was permissible for 30 amps up to 48' and at 40 amps up to 36'.

What I missed was the asterisk which stated for Type TW wire, it wasn't permissible. On another table it states that for TW #10 is rated at 30 amps and #8 at 40 amps.
 

wyliesdiesels

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WoW! Youre really lucky your house didnt burn down! #12 wire would have been too small even under old NEC code cycles!

What does the data plate on the oven say?? #10 may be too sml
 

Mattlt

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Thanks for the help.

In my defense, I originally consulted the 37th edition of Wiring a Simplified written by H.P. Richter and based on the 1993 NEC. It stated that a #12 one way distance with a 2% drop at 240V was permissible for 30 amps up to 48' and at 40 amps up to 36'.

What I missed was the asterisk which stated for Type TW wire, it wasn't permissible. On another table it states that for TW #10 is rated at 30 amps and #8 at 40 amps.


I have the same book, although mine is two versions older. Back up two pages. Look at the table titled Ampacity of Copper Wires. That table is much easier to understand. When in doubt, up-size.
 

ishiboo

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#12 would have gotten hot but handled 31A without burning the house down.

The issue was the loose connection.

But the whole run needs to be replaced.
 

DirtRoad

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12 is only good for 20amps.

You dont need the NEC to figure this stuff out, says right on the package what the wire is rated for.
 
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L8CS

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The original run was 15' to the Subpanel. The oven never flipped a breaker probably because it never operated at full load. The new run is 6' to the Subpanel so why would it trip the breaker now? I think the short runs allowed for less of a voltage drop and therefore the wire never overheated, thus tripping the breaker.

I honestly think that the loose set screw on the breaker caused the copper to overheat because it was arcing across. I have used the oven in the original configuration for (8) years and never tripped anything.

My problem was that I listened to my Dad originally and he convinced me that the short run would be ok. His generation was all about my way or the highway. Fortunately I'm educating myself on the right way of doing things and not just taking someone else's opinion.
 

jmarkwolf

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Regardless of what you got away with in the past, as dirtroad states, 12 is only good for 20A.

Use the right stuff for your application.

That being said, there was a period of time a few years back, where I would get home from work and find the air conditioning off and one of the two big fuses blown in the exterior box. I would replace the fuse and it would work fine for awhile. This happened a couple times.

Then it happened on a weekend when I was home. I went to open the box to investigate again and the metal box was so hot I couldn't touch it! This box is attached to the wood siding on the side of my house! I'm lucky it didn't burn.

Come to find out, the copper "fingers" of the fuseholder had lost much of their spring temper and didn't hold the fuse with enough force, providing a lousy series connection. In addition, the clamping screws on the wire weren't very tight, so I had a double whammy going.

Replaced the whole box with a better fuse "cartridge system" and never had another problem.
 

sberry

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Yes, you need a wire large enough that the appliance connected to it cant overload it with a bit of safety margin. Obviously that aint it.
 

C96

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You guys are missing it here. The reason for the loose connection is because the wiring is too small. That #12 has been overheating from the get go, expanding and contracting for so long the terminals became loose, then started arcing which created more heat causing the breaker to finally trip, thank God.

This could have been much more serious.

OP, get at least #8 for that oven since you claim it draws 31 amps. Install a 40 amp breaker and then you can relax and not worry any longer.

Your oven will love you for it; it will no doubt operate more efficiently.

Good Luck :thumbup:
 

pattenp

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#12 is too small for what? The 30A breaker? 30A breaker connection terminals are usually rated to handle #14 - #8 wire.

You guys are missing it here. The reason for the loose connection is because the wiring is too small. That #12 has been overheating from the get go, expanding and contracting for so long the terminals became loose, then started arcing which created more heat causing the breaker to finally trip, thank God.

This could have been much more serious.

OP, get at least #8 for that oven since you claim it draws 31 amps. Install a 40 amp breaker and then you can relax and not worry any longer.

Your oven will love you for it; it will no doubt operate more efficiently.

Good Luck :thumbup:
 

C96

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#12 is too small for what? The 30A breaker? 30A breaker connection terminals are usually rated to handle #14 - #8 wire.

Too small meaning current-carrying capacity. The #12 wire is inadequate for a 31 amp load. The #12 is only rated for 25 amps but must be protected by an overcurrent device not to exceed 20 amps.
 
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L8CS

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I replaced the 6' section between the oven junction box and the Subpanel with 10-3 with a 30 amp double. One single oven is only drawing 13.6 amps on one side and 12.7 on the other. Both ovens draw 28.6 on one side and 27.2 on the other.

The oven cable itself is only 10-3 braided aluminum. I remember reading that if you use aluminum, you should size it (2) sizes heavier than copper, ie: #4 aluminum instead of #6 copper. So if Bosch only puts 10-3 braided aluminum in their 6' pigtail but rate the oven at 31.5 amps, what are we missing? Are they saying that #12 copper is ok?

I don't know but I'll stay with the 6' length of 10-3 copper.
 

Bmwsyc

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It is probably tinned copper, or nickel plated wire, higher temperature wire. Probably not aluminum.
 
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Bad Habit

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(newbie here)

It is most definitely some higher temperature rated wire on the oven leads.

You can not use #12 for a 30A circuit, it can only be used for a 20A circuit based on the NEC.
You also need to take into account a 20% safety factor when you size circuits. For your 31A load you need to multiply by 1.25 (=38.37, 31 is 80% of 38.37 so you have a 20% safety factor). This means a 40A breaker. This requires #8 copper wire.

Yes you could probably get by with #10, or as it seems you did get by with #12. Just don't expect your insurance company to pay for any of the fire damage if something does happen.
 
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L8CS

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It is probably tinned copper, or nickel plated wire, higher temperature wire. Probably not aluminum.

No it's aluminum. I used both tinned and nickel plated copper in electronics. It was thin, stranded aluminum which cuts and bends easily. The oven is made by Bosch in Germany.
 

C96

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I replaced the 6' section between the oven junction box and the Subpanel with 10-3 with a 30 amp double.

So if Bosch only puts 10-3 braided aluminum in their 6' pigtail but rate the oven at 31.5 amps, what are we missing? Are they saying that #12 copper is ok?

Don’t concern yourself with how the manufacture has wired the unit internally. This oven has already been tested by Underwriters Laboratories and should wear the official UL Certification Mark approved for use in the United States.

What you do need to concern yourself with is the NEC (National Electrical Code). It’s the standard for the safe installation of electrical wiring and equipment in the United States.

What you have done is still a violation of the NEC. The circuit still has the potential of being overloaded.

Since the rating of the oven is 31.5 amps the 30 amp circuit you just installed is a violation. You need to bump it up to #8 AWG copper and a 40 amp breaker.

Not saying it wont work, just letting you know it’s still not in compliance and could result in another potential overload.
 

pattenp

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I know now what you meant. I was taking your statement that the #12 wire was too small for the terminal connections of the 30A breaker. I know very well the requirement for sizing over current protection.

Too small meaning current-carrying capacity. The #12 wire is inadequate for a 31 amp load. The #12 is only rated for 25 amps but must be protected by an overcurrent device not to exceed 20 amps.
 

n8n

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No it's aluminum. I used both tinned and nickel plated copper in electronics. It was thin, stranded aluminum which cuts and bends easily. The oven is made by Bosch in Germany.

The wiring used internal to the oven, from its factory provided connection points to the building wiring, is irrelevant. The ampacity of the breakers and conductors to that point is governed by the NEC so that is what you need to refer to to have a code compliant and safe installation. there are some exceptions for kitchen equipment on a shared circuit and pigtails etc. but in general you will need, for an oven drawing 31A, you want a 40A breaker and #8 wire or a 50A breaker and #6 wire. A 50A receptacle is standard for a plug in installation in a kitchen (and can be used for a welder as well.) If you are hard wiring to the unit, 40A/#8 would be fine but if you are providing a receptacle I would suggest just going ahead and using 50A/#6 for a more standard installation.

These days you are also required to run a 3 conductor plus ground cable, you can no longer just bond the appliance case to the neutral as used to be done with ranges and dryers (the only devices in a typical home that are 240VAC and also use 120VAC power therefore require a neutral.)
 

walrus

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I replaced the 6' section between the oven junction box and the Subpanel with 10-3 with a 30 amp double. One single oven is only drawing 13.6 amps on one side and 12.7 on the other. Both ovens draw 28.6 on one side and 27.2 on the other.

The oven cable itself is only 10-3 braided aluminum. I remember reading that if you use aluminum, you should size it (2) sizes heavier than copper, ie: #4 aluminum instead of #6 copper. So if Bosch only puts 10-3 braided aluminum in their 6' pigtail but rate the oven at 31.5 amps, what are we missing? Are they saying that #12 copper is ok?

I don't know but I'll stay with the 6' length of 10-3 copper.
Again, size the wire according to the instructions, thats the way its UL listed.
 

sberry

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I believe some of the ovens list the max breaker and if this is 2 separate units hooked to one wire then there are ratings for max breaker as per instruction, if each unit comes with 12 they both may be connected to 8 etc.
 
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L8CS

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The wiring used internal to the oven, from its factory provided connection points to the building wiring, is irrelevant. The ampacity of the breakers and conductors to that point is governed by the NEC so that is what you need to refer to to have a code compliant and safe installation.

Apparently the context of my original post has been lost in translation. It wasn't about whether I should have used a larger wire or not, it was about if a loose connection at the breaker could have arced and caused the copper to overheat thus melting the insulation just below the breaker.

Some of us have to make do with the resources that we have and at the time my Dad and I installed the 12-3, that was what we had. Did I know it was wrong at the time? No. Did I educate myself along the way? Yes. The problems with our Fathers are that we put them up on a pedestal and expect them to know the right answer instead of learning the answer ourselves.

But to say what the manufacturer does is irrelevant, and that the NEC is the all knowing OZ is absurd. By some posts referring to the UL testing, one can concur in this case, that Bosch's use of 10-3 Aluminum is enough for their 31.5 amp rating otherwise why would they approve it. So what does Bosch know that we don't.

The NEC rating has a safety buffer built in. Some say its 20%, and others say it's 20 to 30% but irregardless, it's there for a reason. An electrical wire's ability to dissipate heat is not only affected by the size of the conductor, but also by the thickness of the insulation and the ambient air temperature. Therefore they have a safety margin built in to compensate for the variables. Whether the NEC or appliance manufacturers will admit to the safety margin or not. From a legal perspective there would have to be one for liability purposes.

For example the 20 amp outlet you bought at The Home Depot: Do you honestly think it will melt if you push 22 amps through it. I would think not and I'm sure many of you agree. Would I recommend doing it on a continual basis? No. But just like driving 80 MPH in a posted 65 zone. It's a chance we take.

I'm sorry for being long winded but I'm not a contractor worried about getting caught during a building inspection. I'm just a homeowner looking for answers, until I get a 6' length of 8-3 NM cable to replace what I have.

Thanks for the help.
 

ishiboo

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Apparently the context of my original post has been lost in translation. It wasn't about whether I should have used a larger wire or not, it was about if a loose connection at the breaker could have arced and caused the copper to overheat thus melting the insulation just below the breaker.

Yes, and I answered that. A loose connection at the breaker would definitely cause that.

But to say what the manufacturer does is irrelevant, and that the NEC is the all knowing OZ is absurd. By some posts referring to the UL testing, one can concur in this case, that Bosch's use of 10-3 Aluminum is enough for their 31.5 amp rating otherwise why would they approve it. So what does Bosch know that we don't.

What they were saying is the size wire the manufacturer uses on the whip versus what you will run for your circuit is irrelevant. It is. The way these codes/engineering/etc. works is a manufacturer builds the appliance, UL tests it to ensure safety, and then it's a sealed unit... you install it according to manufacturer rules and the NEC.

The NEC does not allow you to run 18ga wire to an outlet because you think you only need it for 4 amps, but the manufacturer can easily put a 16ga cord on the device you planned on plugging in and run 18 or 20ga wire inside as they know exactly what the load will be, and it's a short, known length.

What Bosch knows that you don't is that their wiring is in a controlled environment, a fixed and limited length (very important), and they use appliance wire of a completely different spec. A short length #12 solid wire will safely carry probably 45A with no issues and a very high temperature insulation. Voltage drop, heat dissipation, insulation ratings, etc. all come into play. None of which needs to be known by the end-user (nor explained here) to successfully install an oven - just follow the instructions!

The NEC rating has a safety buffer built in. Some say its 20%, and others say it's 20 to 30% but irregardless, it's there for a reason. An electrical wire's ability to dissipate heat is not only affected by the size of the conductor, but also by the thickness of the insulation and the ambient air temperature. Therefore they have a safety margin built in to compensate for the variables. Whether the NEC or appliance manufacturers will admit to the safety margin or not. From a legal perspective there would have to be one for liability purposes.

Yes, and?

For example the 20 amp outlet you bought at The Home Depot: Do you honestly think it will melt if you push 22 amps through it. I would think not and I'm sure many of you agree. Would I recommend doing it on a continual basis? No. But just like driving 80 MPH in a posted 65 zone. It's a chance we take.

I'm sorry for being long winded but I'm not a contractor worried about getting caught during a building inspection. I'm just a homeowner looking for answers, until I get a 6' length of 8-3 NM cable to replace what I have.

Thanks for the help.

Again, nobody has stated anything to the contrary. Pushing 20A through a 22A outlet is quite different than pushing 31A through a wire that should be breakered for 20A. It's compounded by the fact you couldn't be bothered to correctly torque the breaker screws, creating another hazard and exacerbating the issue.

You already have your answers. #12 was the wrong wire and you've created a safety hazard using it. All electrical connections (as well as hydraulic, gas, etc.) need to be properly torqued for proper operation, and more importantly safety.

You now know #12 is wrong for the application, but you want to rehash the fact that you know it's wrong but it's there until you get 6' of the correct wire? SIX FEET? Seriously? Don't turn the computer on and visit GJ until you've corrected it... perhaps that will be enough motivation for you to get it done. :thumbup:
 

ishiboo

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BTW, how old is this oven? Bosch ovens are made in the US from what I've seen. And I can't imagine thin, finely stranded aluminum for an oven whip. I'm certain it's tinned copper, if not I'd throw that oven out.

If they are really aluminum, it would require special connectors between the wires to go between the two, plus anti-oxidant... what did you use?
 

n8n

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Apparently the context of my original post has been lost in translation. It wasn't about whether I should have used a larger wire or not, it was about if a loose connection at the breaker could have arced and caused the copper to overheat thus melting the insulation just below the breaker.

yes, it's possible.

In any case both the wiring and the breaker must be replaced, now.

Some of us have to make do with the resources that we have and at the time my Dad and I installed the 12-3, that was what we had. Did I know it was wrong at the time? No. Did I educate myself along the way? Yes. The problems with our Fathers are that we put them up on a pedestal and expect them to know the right answer instead of learning the answer ourselves.

But to say what the manufacturer does is irrelevant, and that the NEC is the all knowing OZ is absurd. By some posts referring to the UL testing, one can concur in this case, that Bosch's use of 10-3 Aluminum is enough for their 31.5 amp rating otherwise why would they approve it. So what does Bosch know that we don't.

It's because the wiring is internal to the oven, not the building. Building wiring must conform to NEC, period. If it doesn't good luck with that insurance claim should anything happen. The oven is UL listed as an assembly, so wire sizes lower than that spec'd for a given load by the NEC may be used, if UL decides that everything as assembled is safe.

The NEC rating has a safety buffer built in. Some say its 20%, and others say it's 20 to 30% but irregardless, it's there for a reason. An electrical wire's ability to dissipate heat is not only affected by the size of the conductor, but also by the thickness of the insulation and the ambient air temperature. Therefore they have a safety margin built in to compensate for the variables. Whether the NEC or appliance manufacturers will admit to the safety margin or not. From a legal perspective there would have to be one for liability purposes.

For example the 20 amp outlet you bought at The Home Depot: Do you honestly think it will melt if you push 22 amps through it. I would think not and I'm sure many of you agree. Would I recommend doing it on a continual basis? No. But just like driving 80 MPH in a posted 65 zone. It's a chance we take.

I'm sorry for being long winded but I'm not a contractor worried about getting caught during a building inspection. I'm just a homeowner looking for answers, until I get a 6' length of 8-3 NM cable to replace what I have.

Thanks for the help.

If you can't pass a building inspection, you essentially have no insurance coverage in case of an incident, especially if you did unpermitted work - something to keep in mind.

Whether or not something is safe is irrelevant; if it doesn't meet code it gives your insurance company grounds to deny a claim.
 

D.J.

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If the 12-3 is Romex and in conduit isn't that a violation of the NEC in itself. Seems as though I have read on here before this info, not counting that it should be a #8 with a larger breaker.
 

gc427

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I absolutely love when people ask for help and then ignore the sound advice given.

I guess that the posters that shared facts quoted from the NEC must be full of it?

I'm glad that you don't care and are willing to justify your reckless actions as you see fit. :beer:

Good luck!
 

sberry

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The op has a point but its a combination of issues, the smaller wire poor connection didn't help. One would have never likely known it was under wired with a 10, wouldn't have been an issue and partially because there is a huge margin difference especially once we start down continuous loading.

I am not familiar with the models and havnt digested this whole story but some ovens may be connected to breakers larger than the familiar wiring combo, part of this was eluded to by someone above with the full 50A circuit statement. Like a range oven combo, if this is 2 pc and it comes with 14 wire got to have a 30 brkr and some of them can go to 50A circuits with a 12 whip I believe,,,, its been a while since I read all that word for word.
Let one of the guru's elaborate.
 
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sberry

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If you can't pass a building inspection, you essentially have no insurance coverage in case of an incident, especially if you did unpermitted work - something to keep in mind.

Whether or not something is safe is irrelevant; if it doesn't meet code it gives your insurance company grounds to deny a claim.
No it doesn't,,, its why or half the reason you have insurance, in case you do something wrong. If he was a contractor its a different matter.
They insure millions of faulty installations every day. Wasn't done knowingly by the owner way back when. They collected premiums on a now non event for decades.
 
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L8CS

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It wasn't my intent to start a flame war, so I will speak my piece and move on as some of you have suggested.

When I made my 1st post to this forum, I wasn't asking for help in choosing the correct wire size for my application. I simply asked " I know a loose connection will arc but will a loose connection at the breaker overheat and melt the insulation back?" I wasn't looking for a lecture about using the wrong wire size or a sermon about my house burning down, I was looking for a simple answer to a obvious problem. I should have explained that I didn't have the time to drive (90) minutes to get a 6' piece of 8-3 but I need to get the oven online and I had a piece of 10-3. Was it code, no but you do what you have to do, to survive.

I'm partially to blame on expecting some of you to have a background in Thermodynamics and explain that where the insulation ends on the copper wire, the insulation is no longer partially airtight. And when you add Heat, Oxygen and Fuel, there will be combustion, or melting in this case because the plastic insulation had not yet reached its combustion point. The fact that no one could answer it besides just an obvious "Yes" indicates that some of you don't have the experience and expertise to offer a detailed explanation.

The ends of a wire run or where the insulation has been stretched and therefore thinned out, are the most susceptible to overheating because air can penetrate. When the insulation is stretched thin, more heat leaks out and if the thin point is near a combustible or metal surface, it can either heat or arc possibly causing a fire. Modern Residential and Commercial electrical fires are usually attributed to human error, like driving a staple through the insulation, or improper grounding, thinned or nicked insulation, not having a 12-3 Romex that's pulling 13 amps.

The rest of the dialogue about Aluminum Appliance whips and the NEC being the All and Powerful OZ just shows that some of you don't have the ability to question why.
It also demonstrates how hypocritical those of you that are Contractors can be.

While you're quick to condemn me for using a smaller wire then NEC dictates, I'm sure there's not one Contractor in this Forum that hasn't taken a shortcut by using the wrong size wire in a conduit run or wrapped a splice in a junction box, not twisting the ground wire the correct number of turns in commercial wiring or not even grounding a metal box knowing full well a Building Inspector wouldn't crawl or climb a ladder to check. I've been around Contractors long enough to know it's all about profit and not about principal, and I've yet to see an Electrical Contractor torque anything unless they had to, ie: got caught.

So remember, in John 8:7, it states! "Let any one of you who is without sin be the first to throw a stone."

Enough said. Alpha Mike Foxtrot
 

sberry

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What is it you want,,, some science to splain a severly overheated overloaded wire, how thin insulation matters when its 2 sizes 2 small? How about how a small wire magnified a connection problem then? Overheated the wire and loosened the connection then?
Which came first doesn't much matter and the fire wont care if you didn't have time to drive for the wire?

You did something dumb, no way around it.
 
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mobiledynamics

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I'm just a weekend warrior but what is the definition of torque...

On all my cars, if I have the info or access, I always torque to OEM specs. Just like alot of TTY bolts I replace , whereas I'm sure some Indy's may just reuse over/over.

In the electrical world, whether it be a receptable or breaker, are you guys really using a torque screwdriver. I've done plenty of wiring but have never torqued when I terminated the wires. Just made sure it was snug. The couple times I have used the torque screwdriver was when I was working on some 6/3-8/1 portable cord connectors. I generally just err on the tight side. If it's a receptable (most of mine are back clamps), I start them with a Phillips bot I snug it was a flat, as the flat cams out less and I get it tight. Same goes for panel breakers. Depending on the panel breaker, I go for my Robby screwdriver
 
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n8n

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The rest of the dialogue about Aluminum Appliance whips and the NEC being the All and Powerful OZ just shows that some of you don't have the ability to question why.
It also demonstrates how hypocritical those of you that are Contractors can be.

While you're quick to condemn me for using a smaller wire then NEC dictates, I'm sure there's not one Contractor in this Forum that hasn't taken a shortcut by using the wrong size wire in a conduit run or wrapped a splice in a junction box, not twisting the ground wire the correct number of turns in commercial wiring or not even grounding a metal box knowing full well a Building Inspector wouldn't crawl or climb a ladder to check. I've been around Contractors long enough to know it's all about profit and not about principal, and I've yet to see an Electrical Contractor torque anything unless they had to, ie: got caught.

Well, I actually probably *could* explain to you a lot of what you mention but I don't have to. You don't necessarily need to understand why every provision of the NEC exists, but you do need to conform to it. And I actually have worked not as a field electrician but a project manager supervising field electricians, and I was that guy who frowned on shortcuts, because I never wanted my name, my employer's name, or any of my field guys or subs to be associated with shoddy work. "Liability" is not a fun word.

I've also done my own residential wiring, and I didn't take any shortcuts there either. About the worst you could accuse me of is sloppy stapling, but that's the nature of "old work." I actually did pull a homeowner's electrical permit for some work I did on my last house. I just realized that I needed to correct too much shoddy work that was done previously that it would be evident to anyone that really poked around that there was a lot of new Romex upstairs and again, liability, I wanted that sticker so when I sold the house there wouldn't be anything shady about it.

No, I wouldn't necessarily use a torque screwdriver on a breaker connection, but it's not a horrible idea if you don't have educated fingers. And too tight is far better than too loose in this instance.
 
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