How many #4/0 THHN fit in 2-1/2" PVC Sch 80?
54/0 AWG THHN/THWN-2 wires in 2-1/2" Rigid PVC conduit, Schedule 80
4.119 sq in × 40 % = 1.6476 sq in allowed. ÷ 0.3237 sq in per wire = 5.09, so 5.
This pull in numbers
- 5 wires fill
- 39.3 % of 2-1/2" PVC Sch 80
- Limit for three or more
- 40 %
- For 6 or more
- 3" PVC Sch 80, up to 8
- Pipe to wire diameter
- 3.57 to 1
- In THW insulation
- 4 fit
- In XHHW-2 insulation
- 5 fit
Before you pull 5
- The ground counts. Every wire in the pipe counts toward fill, the green or bare ground and the neutrals too. 5 is the total, not the hots.
- Derating. If all 5 were current-carrying, each would be adjusted to 80 % of its ampacity (Table 310.15(C)(1)): a #4/0 THHN at 260 A in the 90 °C column becomes 208 A. Grounds don't count as current-carrying. How derating works
- Bends. A full pipe pulls hard. Keep to 360° of bends between pull points, less for a tight fill.
#4/0 THHN in other 2-1/2" conduit
| Conduit | Inside area | Most #4/0 THHN |
|---|---|---|
| Electrical metallic tubing | 5.858 | 7 |
| Intermediate metal conduit | 5.135 | 6 |
| Rigid metal conduit (RMC, GRC) | 4.866 | 6 |
| Rigid PVC conduit, Schedule 40 | 4.695 | 6 |
| Rigid PVC conduit, Schedule 80 | 4.119 | 5 |
| Flexible metal conduit (FMC, Greenfield) | 4.909 | 6 |
| Liquidtight flexible metal conduit (LFMC) | 4.881 | 6 |
#4/0 THHN in other PVC Sch 80 sizes
Other wire sizes in 2-1/2" PVC Sch 80
#14: 170#12: 124#10: 78#8: 45#6: 32#4: 20#3: 17#2: 14#1: 10#1/0: 9#2/0: 7#3/0: 6#4/0: 5250 kcmil: 4300 kcmil: 3350 kcmil: 3500 kcmil: 1