So I went and re-read the whole of section 8 of the CEC 2015 (the section about load calculations), and I think you are correct about being allowed to push up to the 200 A limit. What it says is that "the minimum ampacity of service or feeder must be the greater of ... ", where the "of" is the total given by the calculations. I was dead convinced that it was 80% of the total. I did lots of reading over a few weeks, maybe I got confused by it all. Also, one of the electricians that visited for a quote also felt I was over with a 60A circuit for the charger as well (I didn't see his load calculation data though).
However, what isn't clear to me is how that applies to the main breaker for the house. Is that still restricted to 80% or not? Section 8-104 suggests that you can have up to 100% of the rating if the breaker is marked for continuous operation at 100% of the device rating, but if only rated for 80% continuous, then it would obviously be limited to 80%. So there might be some restrictions related to the over-current protection device at the whole house level beyond that of the service size.
I really should have asked the inspector when he was here today...just to get clarification. I'll try asking an electrician I know and see what he says.
Relevant sections of the 2015 CEC code for reference:
8-104 Maximum circuit loading (see Appendix B)
(1) The ampere rating of a consumer’s service, feeder, or branch circuit shall be the ampere rating of the overcurrent device protecting the circuit or the ampacity of the conductors, whichever is less.
(2) The calculated load in a circuit shall not exceed the ampere rating of the circuit.
(3) The calculated load in a consumer’s service, feeder, or branch circuit shall be considered a continuous load unless it can be shown that in normal operation it will not persist for
(a) a total of more than 1 h in any two-hour period if the load does not exceed 225 A; or
(b) a total of more than 3 h in any six-hour period if the load exceeds 225 A.
(4) A load of a cyclic or intermittent nature shall be classified as continuous unless it meets the requirements of Subrule (3).
(5) Where a fused switch or circuit breaker is marked for continuous operation at 100% of the ampere rating of its overcurrent devices, the continuous load as determined from the calculated load shall not exceed
(a) 100% of the rating of the circuit where the ampacity of the conductors is based on Column 2, 3, or 4 of Table 2 or 4; or
(b) 85% of the rating of the circuit where the ampacity of the conductors is based on Column 2, 3, or 4 of Table 1 or 3.
(6) Where a fused switch or circuit breaker is marked for continuous operation at 80% of the ampere rating of its overcurrent devices, the continuous load as determined from the calculated load shall not exceed
(a) 80% of the rating of the circuit where the ampacity of the conductors is based on Column 2, 3, or 4 of Table 2 or 4; or
(b) 70% of the rating of the circuit where the ampacity of the conductors is based on Column 2, 3, or 4 of Table 1 or 3.
(7) If other derating factors are applied to reduce the conductor ampacity, the conductor size shall be the
greater of that so determined or that determined by Subrule (5) or (6).
(8) Notwithstanding the requirements of Rule 4-004(1)(d) and (2)(d), the ampacity of the underground
conductors shall not exceed in any case those determined by Subrules (5)(b) and (6)(b) of this Rule.
8-110 Determination of areas
The living area designated in Rules 8-200 and 8-202 shall be determined from inside dimensions and include the sum of
(a) 100% of the area on the ground floor;
(b) 100% of any area used for living purposes on the upper floor; and
(c) 75% of the basement area.
8-200 Single dwellings (see Appendices B and I)
(1) The minimum ampacity of service or feeder conductors supplying a single dwelling shall be based on the greater of Item (a) or (b):
(a) (i) a basic load of 5000 W for the first 90 m2 of living area (see Rule 8-110); plus
(ii) an additional 1000 W for each 90 m2 or portion thereof in excess of 90 m2; plus
(iii) any electric space-heating loads provided for with demand factors as permitted in Section 62
plus any air-conditioning loads with a demand factor of 100%, subject to Rule 8-106(4); plus
(iv) any electric range load provided for as follows: 6000 W for a single range plus 40% of any
amount by which the rating of the range exceeds 12 kW; plus
(v) any electric tankless water heaters or electric water heaters for steamers, swimming pools, hot tubs, or spas with a demand factor of 100%; plus
(vi) any electric vehicle supply equipment loads with a demand factor of 100%; plus
(vii) any loads provided for in addition to those outlined in Items (i) to (vi) at 25% of the rating of each load with a rating in excess of 1500 W if an electric range has been provided for, or 100% of the rating of each load with a rating in excess of 1500 W up to a total of 6000 W, plus 25% of the load in excess of 6000 W if an electric range has not been provided for; or
(b) (i) 100 A where the floor area, exclusive of basement floor area, is 80 m2 or more; or
(ii) 60 A where the floor area, exclusive of basement floor area, is less than 80 m2.
(2) The minimum ampacity of service or feeder conductors from a main service supplying two or more dwelling units of row housing shall be based on
(a) Subrule (1), excluding any electric space-heating loads and any air-conditioning loads, with application of demand factors to the loads as required by Rule 8-202(3)(a)(i) to (v); plus
(b) the requirements of Rule 8-202(3)(b), (c), (d), and (e).
(3) Notwithstanding Rule 86-302, the total load calculated in accordance with either Subrule (1) or (2) shall not be considered to be a continuous load for application of Rule 8-104.