Years ago I was working with some local bar bands, handling some of the sound and lighting duties. I owned a 120 foot long hank of 4 conductor 4awg SO portable power cable. We were playing one show with a bigger headliner band. We had the wise idea that we'd just hang all the lights from both bands. Most all the cans were PAR64's with 500 or 1000 watt lamps, there were about 50-60 fixtures along with a few small pin spots etc.
About 1/2 way through the show, I was doing a walk around and checking up on things and I grabbed the cable and it was HOT, not so as you couldn't touch it but over 100 deg F for sure. This cable is about 1-1/4" in diameter. I did some quick mental math and figured the total lighting load to be around 30,000 watts. This would mean about 125 amps per hot in that cable! The even more crazy part was that I was connected into an open 200m main panel with Mueller clips (photo) directly to the bus plates.
I don't disagree that it always is a good idea to err on the side of caution, especially if the wiring is used when unsupervised. But just because there is a little cable warming, doesn't mean there is a problem. I worry more about the plugs and outlets, that is often were the concentrated resistance is and why your vacuum cleaner plug sometimes feels warm when you unplug it.

About 1/2 way through the show, I was doing a walk around and checking up on things and I grabbed the cable and it was HOT, not so as you couldn't touch it but over 100 deg F for sure. This cable is about 1-1/4" in diameter. I did some quick mental math and figured the total lighting load to be around 30,000 watts. This would mean about 125 amps per hot in that cable! The even more crazy part was that I was connected into an open 200m main panel with Mueller clips (photo) directly to the bus plates.
I don't disagree that it always is a good idea to err on the side of caution, especially if the wiring is used when unsupervised. But just because there is a little cable warming, doesn't mean there is a problem. I worry more about the plugs and outlets, that is often were the concentrated resistance is and why your vacuum cleaner plug sometimes feels warm when you unplug it.
