I'm in the process of installing a new 200A electrical service to an existing residence. I will be pulling three 3/0 Cu THHN cables through 2 inch rigid conduit. The first run is from the service head to the meter-main and is a straight vertical run of about 15 feet. I'm not too worried about that one. The second run is from the meter-main to the load center. It comes out the side of the meter-main into a 3/4 inch offset followed by a 45 degree el which turns up, a straight run of about 3 feet on the 45, another 45 degree el back to the horizontal, 8 feet of straight run, a 90 degree condulet (still in the horizontal) and an 8 inch nipple into the back of the load center.
The question is, what is the best way to pull the cables? One at a time or all three at once? Is there any special tricks I should know about? What about getting the cable to go around the condulet? Any help would be appreciated?
Cables are pulled all at once, and not around sharp corners. You have to access the corners, take off the fittings, and pull pretty much in straight lines only. Well, slight bends might be OK.
The pipe size looks to be good for 5 conductors, so it should be a fairly easy pull.
It sounds as if you are making 2 separate pulls. Make sure you have pulling soap. The best method is to soap and push the wire. The person pulling on the fish tape/rope needs to just keep a slow steady pressure, the force should be coming from the pushing end. ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ Keep the whole world singing . . . . DanG (remove the sevens) snipped-for-privacy@7cox.net
As was earlier stated, pull them all at once. And if you don't have a fish tape, you can "pull" a string in with a vacuum cleaner and use the string to pull in a rope or something strong enough to pull the wires.
When I put in a 200A service a couple of years ago, I used 2 1/2 " plastic conduit. In our local codes, only 5 feet is permitted between the meter box and service panel. My journeyman sub suggested the larger size, so I traded all the 2" fittings and conduit I had for the 2 1/2" and I'm glad I did because even in the short distance we had two 90 degree els plus the bend into the box and it was one real hassle. Some power companies (like ours) allow 2/0 copper for residential and that would be easier with 2" conduit and lots of pulling lube.HTH
There are all kinds of tricks for pulling/terminating larger conductors. Unfortunately, it's easier/better to show someone the tricks than to write them down, a learn by doing/watching kinda thing. One approach is to install the base of the weatherhead on the conduit, then install each conductor separately. Pre-strip each conductor (sized to fit the lugs) before pushing it in from the roof. Helps to give the very end of the (stripped) wire a wrap of black tape before inserting it into the conduit, to keep it from fraying/catching on a fitting. Once the wire enters the meter, the person at the meter removes the black tape, then brings the conductor straight into the lug and tightens the lug screw. Helps to start with the neutral (don't forget to mark it). Repeat for each conductor. Don't force the wires if they catch (usually at the fitting at the meter) Pull it back some and try pushing again. Once the conductors are all in, pre-bend the conductors at the weatherhead, then assemble the weatherhead. Leave at least 3 or 4 feet hanging from the weatherhead.
You should pull/push _all_ of the conductors in at the same time in this part of the run. Don't try to terminate at the same time like from the weatherhead to the meter, though. Sometimes, on a short run, you can get away with duct taping all of the conductors together, apply a little wire lube to the head and push all of them through. If that doesn't work, you'll have to fish in a 1/4" rope and connect all the wires to that and pull it through.
Once the wires are pulled from the panel to the LB, have a helper at the panel and then feed the wires from the LB one at a time. Talk through the
8" nipple to the helper so that he/she is pulling while you are pushing and/or taking pressure of the wire. It's _not_ as easy as it sounds. Try not to cross the wires in the LB, if possible.
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