4.

Electrical installation design of a consumer

The generation, transmission and distribution systems outside the consumer premise are usually the property of utility companies
such as EEPCO while power systems in the consumer premises is under the control and responsibility of the consumer. This
course is limited to the design, construction and inspection aspects of electrical installation systems within the consumer
premises.

Fig. 4.1 Electrical Power System comprises of generation, transmission, distribution and consumption

The main objective of this electrical installation course is thus the safe, effective and economical electrical installation circuit
design and construction in the premises of the consumer.

4.1. Control of supply at the consumer premises

The scope of electrical installation in this course is limited to the domain of the consumer premises. The kWh/kVAR meter,
usually owned by a power utility, establishes the boundary between the utility and the consumer. The overhead/underground
cable conductor feeding power from the last pole of the utility company to the consumer building where the conductors are
supported by insulated strains is called service drop. The service conductor is cable from the building strain insulator to service-
entrance equipment.

Utility companies and building code standards describe service requirements. For example the following is extracted from
EBCS-10 pp144.

Clearance from Building opening

i. Service conductor installed as open conductor or multi-conductor cable without any overall
other jacket shall have a clearance of not less than 925 mm from windows, doors, porches, fire
escape, or similar locations.
ii. Service conductors shall not be installed beneath openings through which materials may be moved, such as openings
in farm and commercial buildings.
iii. Overhead wire shall not be run such that they obstruct entrance to these buildings openings.

The service-entrance equipment is a system including at least three elements. This is because it is essential that the consumer
supply should be effectively controlled and also that all switch gear should be accessible. The main switch gear installation
should consist of:
a) means of isolation the supply
b) means of protection against excess current due to overload or short circuit (plus earth-leakage protection if required),
c) Means of measuring the energy.

A main switch containing a fuse for single phase (3 fuses for 3 phase) fulfills these conditions as the switch isolates the supply
while the fuse/s protect/s the circuit against excess current due to over load, short circuit or a serious earth fault.

1
An automatic circuit breaker (ACB) does the job of both the main switch and fuses but at a higher price.
The figures below show the common method of controlling the incoming supply

Figures: Typical service-entrance equipment for a residential or small commercial customer

The main and sub distribution boards (MDB and SDBs) are simply assemblages of parts, including one or more fuse and/or
circuit breakers on copper bus bars arranged on rails/bridges for the distribution of electrical power to the final sub-circuits or to
other sub distribution boards.

A medium or high voltage supplied consumer usually uses three phase supply without/with step down transformer as well as a
meter for measuring both true and reactive electric energies. They may accordingly be equipped with power factor correction
apparatuses to optimize their energy utilization cost.

In addition all essential switchgear and mini substation components are required.

Service-entrance equipment and feeder cable

The selection or knowledge of voltage level of service-entrance from utility company is the first step for the design of the
service-entrance equipment.

Cable from the utilities operating company line to the energy meter at the consumer’s intake point is called the service cable or
line. The service line voltage level is determined by the power requirement of the consumer premises. If the power requirement
is high it is economical to have a high voltage service so that the cable cross sectional area is acceptable. In this case, a
transformer is required in the consumer premises. In Ethiopia power is supplied to industrial premises at 15 kV which is the
distribution voltage while it is at 380/220 Volts for low power consuming commercial and residential consumers.

In industrial and commercial power systems, substations including transformers, reactors, pf correctors, switchgear and standby
generators can be part of the electrical system to be designed, installed and inspected.

2
 Fig. Typical sub-station for medium or high voltage supplied consumer
4.2. Arrangement of installation components

Inside the consumer’s premises there are basically two ways of distributing power i.e. MDB-to-SDB interconnection. These are
illustrated below.

Figure a) Only from MDB to SDB b) from MDB to SDB and from SDB to SDB

3
Example: Let there be three buildings B1, B2 and B3 and they consume powers of 30kW, 20kW and 15kW respectively. The
arrangements of the DB’s using
(a) becomes

Using (b) becomes

In a) failure of SDB 1 does not affect SDB 2 while in b) it does affect. In b) SDB 1 should have a capacity of 35 kW for the
20kW branch and for SDB 2. In a) while the over all cables length is relative to (b) larger, its sizes (cross section) are small. In b)
over all cable length is shorter but between B1 and B2 the cable size is larger.

Because of cable and protective device cost, the MDB as well as the SDBs are installed in a position chosen such that minimum
cable cost is required but at the same time convenience of power delivery, maintenance etc should be satisfied. MDBs are usually
situated in an area where maximum power is consumed which may be determined using moment method of the SDBs to
optimize the costly large sized feeder cable, protective devices and switchgears. The actual/approximate position is then chosen
accounting ease of mounting.

Bldg 1

SDB1 Bldg 2
y
P1, (x1, y1) Bldg x SDB2
P2, (x2, y2)

MDB
PM, (xP, yP) PM, (xM, yM)

Last pole x
of utility

Bldg y
P3, (x3, y3) SDB3
Bldg 3

In the above illustration the ideal position of the MDB is determined as

4
 PM .x p + P1 .x1 + P2 .x 2 + P3 .x 3 PM .y p + P1 .y 1 + P2 .y 2 + P3 .y 3
xM = and yM =
PM + P1 + P2 + P3 PM + P1 + P2 + P3

The MDB is then mounted to the nearest building, say Bldg x.

Electrical installation design in general is the engineering process of selection and decision on the required materials, accessories
and protective devices. Depending on the particular need for residential, public, commercial and industrial customers two or
more of the following are involved in the installation design:
o Lighting installation & fitting
o General purpose socket outlet
o Power (and special purpose) socket outlet
o Trunking/feeder installations,
o Main switchgear feeders
o Sub-mains and distribution gears
o Earthing system,
o Lightening protection systems
o Substation cables
o Substation transformers
o Substation switchgear,
o Power factor correction apparatuses

In electrical installation terminology, a branch circuit or a final circuit is the last portion of the installation in which one or
more parallel connected loads are supplied with electric power as well as use one common isolating and protective devices.
However, each load in a branch circuit is controlled separately with its own control such as a switch or a starter/contactor.

Thus, the following constitute a branch circuit:

o a high power socket outlet (such as for cooking range, stove or boiler),
o a motor supply circuit,
o a group of light points,
o a group of general purpose socket outlets,
o a small group of light points plus small number of low power socket outlets etc

A branch circuit is fed power from an SDB or directly from an MDB and for this purpose it will be provided with a common/one
sized branch circuit feeder cable or set of conductors along its length.

The cable or set of conductors used to connect MDB with each SDB or SDBs with SDB is called a feeder cable or line

4.3. Wire and cable size selection for known constant loads

Once a wire or a cable type is selected based on the mechanical, chemical and thermal strength it will be subjected to for the
particular application, the cable size is to be selected next. Refer to section 4 of EBCS-10 for definitions and regulations related
to cable.

All conductors have resistance that prevents an unlimited flow of current and of course voltage drop. For any given load, we
must select a size of conductor that limits voltage drop to a reasonable value.
Furthermore, current through a wire causes heat due to the inherent resistance and proportional to the square of the current. There
is a limit to the degree of heat that the various types of insulation can safely withstand. Even a bare wire must not be allowed to
reach a temperature that might cause fire. Codes specifiy the ampacity (the max. current- carrying capacity in amperes) that is
safe for a conductor of different sizes with different kinds of insulation and under different operating circumstances.

The size should neither be so small so as to have a large internal voltage drop and large heat nor be too large so as to cost too
much.

5
When selecting the size of a conductor or cable to be used in an installation there are two main factors to be considered:
i) The voltage drop caused by the resistance of the cable of the required length must not exceed a limit given as a standard.
Usually drops of up to 2.5% of the supplied voltage is tolerable.

For feeder cables 1%, for branch circuits (sub circuits) 2%, and equipment taking power directly 2.5% of the supply
voltage drop is tolerable.

ii) The wire or cable must be able to carry the maximum current liable to flow in the circuit without undue heating.

The current rating of a conductor is defined as the maximum current it can carry continuously without undue heating.

iii) Cable size selection may also be affected by the operating temperature of the cable and this should be compensated with
what is known as derating factor
iv. Cable size selection is also affected by grouping, their spacing distance, whether they are underground or in open air as
well as insulation factors

Note: Individual conductor wires and each conductor of a cable are manufactured in the following
international standard sizes in which the wires are circular and may be solid or stranded.

Standard
nominal
cross
section 0.5 0.75 1 1.5 2.5 4 6 10 25 35 50 70 95 120 150 185 240 300 400 500 630
of bare
wire
(mm2)
Purpose Data Electric power cables: for lighting, general purpose and power socket outlets, feeders etc
cable etc

4.3.1. Cable size selection accounting voltage drop calculation

4.3.1.1 Using pure analytical method (without table reference)

4.3.1.1.1 Cable/conductor size selection for dc and single phase wires

DC circuits
a) Using line constants
Consider the two wire circuit (single phase) shown next

The voltage drop on the pair of cable must be ∆V = V1 – V2 2IR

σA ; R in Ω, L in meters, A in mm2 and σ in m/Ω-mm2

where R = L/σ

For copper σ = 57 m/Ω-mm2 (i.e in unit of meter per ohm mm2 ) and for aluminum σ = 33 m/Ω-mm2
Thus cross sectional area of the wire can be related to the loading must satisfy

6
 ∆V σA
2IR = 2IL/σ

or

A (mm2) σ∆V
2IL(m)/σ …….. 4.1

If ∆V is in percentage of the rated value [i.e C = (∆V/V)100% or ∆V = C V/100], then

A (mm2) 200 x I [A] x L[m]/ σCV

If power is given instead of current
A (mm2) 200 x P[W] x L[m]/ σCV2 …….. 4.2

Note in lighting designs voltage drop of up to 5% of rated value are allowed [EEPCO regulation 2.5% max]. In power
applications voltage drop of up to 7% of rated values may be allowed. ]

Example:
A 1 kW electric appliance is to be supplied from a 220V from a single phase source 200m away. Assuming an allowed 2.5%
voltage drop, what cross sectional area of copper wire must be used.

Solution:
A (mm2) 200 x 1000W x 200m/(57 x 2.5 x 2202 ) = 5.8 mm2

Since 2 x 5.8mm2 cable is not available in the standard, the next higher size, i.e. 2 x 6 mm2 cable will be used.
Single phase AC circuits (includes cable inductance considerations)

We note that equation 3.2 does not account the effect of cable inductance and load power factors.

Consider the following single phase circuit with an ac load and a pair power line of length L, resistance R and inductive
reactance X creating a phase difference of δ between the source and load voltages:

From the phasor diagram (considering the real axis is along the load voltage VL and the imaginary axis is perpendicular to VL)
we see and may write for the source voltage
Vs = Vs (cos δ + j sin δ)

Vs cos δ = VL + IR cos ϕL + IX sin ϕL

Vs sin δ = IX cos ϕL - IR sin ϕL
=> Vs = [(VL + IR cos ϕL + IX sin ϕL)2 + (IX cos ϕL - IR sin ϕL)2]0.5

To a first degree approximation, since δ ≈ 0 (due to the fact that X << R for the line) we may neglect sin δ = 0 and cos δ = 1
so that

Vs = VL + IR cos ϕL + IX sin ϕL

7
 |∆V| = |Vs - VL | = [(∆VR)2 + (∆Vx)2] 0.5 = [ ( IR cos ϕL)2 + (IX sin ϕL)2] 0.5

If further the reactance X is negligible (as usually so), then

Vs = VL + IR cos ϕL
|∆V| = |Vs - VL | = IR cos ϕL

The resistance R considered above is the total resistance of the pair of wires. If we consider R is only for one of the wire pair
then the total resistance becomes 2R and thus
|∆V| = |Vs - VL | = 2IR cos ϕL

Consider the following rule of thumb data on inductance:

X = 0.4 Ω/km for over head lines and
X = 0.1 Ω/km for cables
More exact values of inductance for overhead lines can be found from the following formula:

i) for one pair of conductors D meters apart center to center and an effective radius of r’ for each conductor, the inductance is
given by

L = [1 + 4 ln (D/r’)] x 10-7 H/m or approximately L = 0.92 log10 (D/r’) mH/km

ii) three phase lines symmetrically spread in an equilateral triangle corners of side D meters and an effective radius of r’ for each
conductor

L = 0.5 x [1 + 4 ln (D/r’)] x 10-7 H/m or approximately L = 0.46 log10 (D/r’) mH/km

For smooth round conductor r’ = e0.25r where r is the actual radius of the conductor. For practical conductors, r’ is provided by
the manufacturer.

Example: Each conductor of a copper cable of length 200m has a cross sectional area of 10mm2. The cable supplies power to a
220V single phase motor of 5 kW rating that works on full load at cos ϕ = 0.87 and efficiency of 87%.
Determine
a) the sending side voltage required
b) the power loss in the cable
c) the inductance voltage drop using
i the rule of thumb
ii the exact inductance formula if D = 2 cm and f = 50Hz

Solution:
a) Vs = Vr + ∆VR = where ∆VR = 2IR cos ϕL
σA, Rph = 200/ (57 x 10) = 0.35 Ω
Resistance of the conductor of the cable pair, R = L/σ

Noting that = Po/Pin = P/(V.I. cos ϕL ) or I = P/( VLcos ϕL )

Thus, the current in each conductor, I = P/( VLcos ϕL ) = 5000/(0.87 x 220 x 0.87) = 30 A

∆VR = 2 x30 x 0.35 x 0.87 = 18.27 V

=> Vs = 220 + 18.27 = 238.27 V
b) Ploss = 2I2R = 2 x 302 x 0.35 = 630 W

c) Using the above approximate value

∆Vx = 2 I X sin ϕL = 2 x 30 x (0.1Ω/km x 0.2 km) x 0.493 = 0.59 V

We see ∆Vx << ∆VR
8
 Reactive power in the cable would be Q = 2I2X = 2 x 302 x 0.1 H/km x 0.2km = 36 var

Generally for an ac load of power factor cos ϕ, the voltage drop across a cable neglecting its inductance is given by
∆V = 2RI cos ϕ

Since , R = L/σA,

∆V = 2 I L cos ϕ/(σA )

and
A(mm2) = 2LI cos ϕ/(σ
σ ∆V)

Also, since I = P/( V cos ϕ)

A (mm2) =2Lcos ϕ [P/( V cos ϕ)]/ (σ

σ ∆V)
= 2LP/( σV∆ ∆V)

If ∆V is in percentage of the rated line voltage V, i.e ∆V = C V/100, then

A(mm2) = 200 LI cos ϕ/( σ C V) or

A (mm2) = 200 LP/( σ C V2)

Lost power in %, PL%= (PL /P ) x 100

= [2RI2/ ( V I cos ϕ)] x 100
=200 RI/ ( V cos ϕ)

and with R = L/σA,

PL%= 200 L I/( σA Vcos ϕ)

Or since I = P/( V cos ϕ) , PL%= 200 L [P/( V x cos ϕ) ]/ ( σ A V cos ϕ)

2
=> PL%= 200 LP/( σ A V2 cos2 ϕ)
Example:
At the end of a line of 50 m length, a single phase motor of 4kW, 220V, cos ϕ = 0.8 and efficiency = 0.82 is connected. Voltage
drop is 6.6V. Determine the cable size and percentage of lost power in the cable..

Solution
i) A(mm2) = 2LP/( σV∆V) = 2 x 50 x 4000/(0.82 x 56 x 220 x 6.6) = 5.99 mm2 , choose 6 mm2

Or C = (6.6/220) x 100 = 3 %
=> A (mm2) = 200 LP/( σ C V2) = 200 x 50 x 4000/(0.82x56x3x2202) = 5.99

2
ii) PL%= 200 LP/( σ A V2 cos2 ϕ) = 200 x 50 x 4000/(0.822 x 56 x 6 x 2202 x 0.82) = 5.7 %

Or PL%= 200 L I/( σA Vcos ϕ) where I = P/( V cos ϕ) = 4000/(0.82 x 220 x 0.8) = 27.72A
PL%= 200 x 50 x 27.72/(0.82 x 56 x 6 x 220 x 0.8) = 5.71%

4.3.1.1.2 Cable size calculation with voltage drop in unbranched three phase wires

General ac load (reactive + resistive)

9
The sending side line voltage Vs has a phase shift of ϕs w.r.t the current I. The receiving side line voltage is Vr with a phase shift
of ϕ w.r.t the load line current I.

The triple wire power cable of length L is assumed to have only resistance R in each line but negligible inductance.

Lost power on cable ∆P = PS - Pr = 1.73 I x Vs cos ϕs - 1.73 I x Vr cos ϕ

= 1.73 I (Vs cos ϕs - Vr cos ϕ)
= 3 I 2R

With proper phasor diagram of the receiving end as well as the sending end phase, line and resistance drop voltages it can be
shown that the line voltage difference b/n Vs and Vr becomes:
∆V = 1.73 I R cos ϕ

and with R = L/σA, ∆V = 1.73I L cos ϕ/(σ

σA)

=> A(mm2) = 1.73 L I cos ϕ/(σ

σ ∆V)

Also, since I (A) = P/( 1.73 Vcos ϕ)

A (mm2) = 1.73 L [P/( 1.73 Vcos ϕ) ] cos ϕ/(σ ∆V)

=> A (mm2) = L P /( σ ∆V V)

If ∆V is in percentage of the rated line voltage V, i.e ∆V = C V/100 [i.e (∆V/V)100% = C], then
A(mm2) = 173 L I cos ϕ/(σ σ C V)
or

A (mm2) = 100 L P /( σ C V 2)

Lost power in% , PL%= (PL /P ) x 100

= [3 RI2/ (1.73 V I cos ϕ)] x 100
= 173 RI/ ( V cos ϕ)
and with R = L/σA, PL%= 173 L I/( σA V cos ϕ)
Or since I = P/(1.73 V cos ϕ), PL%= 173 L [P/(1.73 V cos ϕ) ]/ ( σ A V cos ϕ)

2
=> PL%= 100 LP/( σ A V2 cos2 ϕ)

Example 1: Sixty incandescent lamps of 100W each are connected to a three phase mains of 220/380V. Length of the line is
50m. Admissible voltage drop is 5V.
Determine i) the size of the conductor per phase.
ii) PL%

Solution: Here cos ϕ = 1; = 1, P = 60 x 100 = 6000W; V = 380V; L = 50m, ∆V = 5V

i) A = L P/(σ ∆V V) = 50 x 6000/(56 x 5 x 380) = 2.8 mm2 => choose 4 mm2.

10
 ii) PL% = 100 L P /(σ AV2) = 100 x 6000 x 50/(56 x 4 x 3802) = 0.92%
Example 2:
A total power of 11kW is to be transmitted over a distance of 90m in a three phase mains of 220V. The power factor cos ϕ = 0.8
and voltage drop C = 5%. Determine the size of the conductor and the lost power in %.
Solution: Here = 1
i) A (mm2) = 100 L P /( σ C V2)
= 100 x 90 x 11,000/(1 x 56 x 5 x 2202) = 7.3 mm2 => choose 10 mm2
a. PL% = 173 x I x L/(σ x A x V x cos ϕ)
I = P/(1.73 x V x cos ϕ) = 11,000/(1.73 x 220 x 0.8) = 36 A

Thus, PL% = 173 x 36 x 90 /(56 x 10 x 220 x 0.8) = 5.6%

If multiple loads of different power factors are connected in parallel at a single point at the receiving end of a cable of length L,
the power factor of the largest one is used for calculation of the cable size (i.e. cos ϕ = max[pf1, pf2, …,pfn) in which also the
total current can be approximated from

I = ( Pi)/1.73 x V x cos ϕ

4.3.1.1.3 Branched lines

A) Two wire system [AC or DC (for which cos ϕ = 1)]

i) Line with equal/uniform cross section but differing voltage drop

Here, the voltage differences should be determined individually and used in the
formula. If in the formulas simply the arithmetic sum of the actually flowing
currents, not their geometrical sum, is used, there results occasionally a somewhat
larger cross section. In general, calculation with simple sum is sufficiently accurate.

Cross section of the cable is obtained from the sum of all current moments (instead of
one moment).

The overall voltage drop across the whole length L3 is given by the sum of section voltages as (approximately if not phasor
addition)

∆V = ∆Vs1 + ∆Vs2 + ∆Vs3

= 2Rs1 Is1 cos ϕ1 + 2Rs2 Is2 cos ϕ2 + 2Rs3 Is3 cos ϕ3
= (2/σ) [(L s1 I s1/A s1) cos ϕ1 + (L s2 I s2/A s2) cos ϕ2 + (L s3 I s3/A s3) cos ϕ3 ]

If a uniform cross section A is used all along L3, then

2 × ( I s1 × L s1 cos ϕ1 + I s 2 × L s 2 cos ϕ 2 + I s 3 × L s 3 cos ϕ 3)

∆V =
σ×A
2 × ( I s1 ×L s1 cos ϕ1 + I s 2 × L s 2 cos ϕ 2 + I s 3 × L s 3 cos ϕ 3)
and A = mm2
σ × ∆V

Approximating (by ignoring the different phase angles of the currents),

I s1= I1 + I2 + I3 ; I s2 = I2 + I3; I s3 = I3
and assuming a mean power factor value of cos ϕ is used,
L s1 I s1 + L s2 I s2 + L s3 I s3 = L s1 (I1 + I2 + I3 ) + L s2 (I2 + I3) + L s3 I 3
= L s1 I1 + (L s1 + L s2) I2 + (L s1 + L s2 + L s3 )I 3
Thus with L s1 = L 1; L s1 + L s2= L 2 ; L s1 + L s2 + L s3 = L 3 we see that
L s1 I s1 + L s2 I s2 + L s3 I s3 = L1 I1 + L2 I2 + L3 I3
11
 2 × ( I 1 L 1 + I 2 L 2 + I 3 L 3 ) cos ϕ 2 × ( I 1 L 1 + I 2 L 2 + I 3 L 3 ) cos ϕ
=> ∆V = and A = mm2
σ×A σ × ∆V
We also see that

I1 × L1 + I 2 × L 2 + I 3 × L3
Lm = m is the average or effective length of cable
I1 + I 2 + I 3

2 × Lm( I1 + I 2 + I 3) cos ϕ
and A= mm2
σ × ∆V

Example 1: Let I1 = 5A; I2 = 8A; I3 = 4A; L1 = 7m; L2=11.5m; L3 = 16m; ∆V = 1.1V and average power factor is 0.85

Required: size of cable

Solution

A = 2 x ( 5 x 7 + 8 x 11.5 + 4 x 16)x 0.8/(56 x 1.1) = 4.88 mm2 => choose 6 mm2

If we calculate the size with mean length Lm

Lm = ( 5 x 7 + 8 x 11.5 + 4 x 16)/(5 + 8 + 4) = 11.24 m;

A = 2 x 11.24 x ( 5 + 8 + 4) x 0.8/(56 x 1.1) = 4.88 mm2 , we again choose 6 mm2

Example 2: Given I1 = 20A; I2 = 15A I3 = 10A; L1 = 10m; L2 = 18m L3 = 25m;

cos ϕ1 = 0.82, cos ϕ2 = 0.79, cos ϕ3 = 0.77 ; ∆V = 1.4V

Required: A
Choose mean cos ϕ = 0.80
A = 2x(20 x10 + 15 x 18 + 10 x 25)x 0.8/56 x 1.4 = 14.5 mm2 => choose 16mm2

ii) Lines with uniform voltage drop in the sections but different cross sections
a) Voltage drop distributed uniformly over all sections

Here the admissible voltage drop is divided by the

number of sections n

For each sectional voltage drop the cross section is determined separately,

i.e ∆Vsi = ∆VT/n

and
Asi = 2 Isi x Lsi cos ϕ/(σσ x ∆Vsi) ;
Where si = 1, 2, ..., n are section indices
And Is1 = I1 + I2 + I3 ; Is2 = I2 + I3; Is3 = I3

Example:
Given I1 = 30A; I2 = 20A I3 = 15A
Ls1 = 10m; Ls2 = 8m Ls3 = 7m
∆VT = 1.2V
Required: As1 , As2 , As3

Solution
Is1 = 30 + 20 + 15 = 65A; Is2 = 20 + 15 = 35A; Is3 = 15A

12
∆Vs1 = ∆Vs2 = ∆Vs3 = 1.2V/3 = 0.4V

Thus Asi = 2 Isi x Lsi/(σ x ∆Vsi)

As1 = 2 x 65 x 10/(56 x 0.4) = 57mm2 choose 70 mm2

As2 = 2 x 35 x 8/(56 x 0.4) = 24.6 mm2 choose25 mm2
As3 = 2 x 15 x 7/(56 x 0.4) = 9.2mm2 choose 10 mm2

b) Voltage drop distributed over the individual sections in accordance with the current load

Here the admissible voltage drop is to be distributed over the individual sections in the ratio of the currents flowing through
them.

i.e. ∆Vs1 : ∆Vs2 : ∆Vs3 = Is1 : Is2 : Is3

Example: Solve problem under a)

Solution

Is1 : Is2 : Is3 = 65: 35 : 15 = 13 : 7: 3 => 23 parts (13 + 7 + 3)

Thus one part (out of 23 ) of voltage drop = 1.2/23 = 0.052V

∆Vs1 = 13 x 0.052 = 0.68 V
∆Vs2 = 7 x 0.052 = 0.36 V
∆Vs3 = 3 x 0.052 = 0.16 V
Accordingly,
As1 = 2 x 65 x 10/(56 x 0.68) = 35 mm2 exact!
As2 = 2 x 35 x 8/(56 x 0.36) = 27.3 mm2 choose 35 mm2
As3 = 2 x 15 x 7/(56 x 0.16) = 23 mm2 choose 25 mm2

4.3.1.1.4 Three phase system 3 or 4 wire and ac load with inductive comp.

The overall voltage drop across the whole length L3 is given by

the sum of section voltages as

∆V = ∆Vs1 + ∆Vs2 + ∆Vs3

= 1.73 Rs1 Is1 cos ϕ1 + 1.73 Rs2 Is2 cos ϕ2 + 1.73 Rs3 Is3 cos ϕ3
= (1.73 /σ) [(L s1 I s1/A s1) cos ϕ1 +
(L s2 I s2/A s2) cos ϕ2 + (L s3 I s3/A s3) cos ϕ3 ]
If a uniform cross section A is used for each phase conductor all along L3,
then

1.73 × ( I s1 ×L s1 cos ϕ1 + I s 2 × L s 2 cos ϕ 2 + I s 3 × L s 3 cos ϕ 3)

∆V =
σ×A
1.73 × ( I s1 × L s1 cos ϕ1 + I s 2 × L s 2 cos ϕ 2 + I s 3 × L s 3 cos ϕ 3)
and A = mm2
σ × ∆V

Approximating (by ignoring the different phase angles of the currents),

I s1= I1 + I2 + I3 ; I s2 = I2 + I3; I s3 = I3
and assuming a mean power factor value of cos ϕ is used,
L s1 I s1 + L s2 I s2 + L s3 I s3 = L s1 (I1 + I2 + I3 ) + L s2 (I2 + I3) + L s3 I 3
= L s1 I1 + (L s1 + L s2) I2 + (L s1 + L s2 + L s3 )I 3
Thus with L s1 = L 1; L s1 + L s2= L 2 ; L s1 + L s2 + L s3 = L 3 we see that
13
 L s1 I s1 + L s2 I s2 + L s3 I s3 = L1 I1 + L2 I2 + L3 I3

1.73 × ( I 1 L 1 + I 2 L 2 + I 3 L 3 ) cos ϕ 1.73 × ( I 1 L 1 + I 2 L 2 + I 3 L 3 ) cos ϕ

=> ∆V = V and A = mm2
σ×A σ × ∆V
Example
Given: Three branched three phase loads with the following data:
P1 = 2.5kW, P2 = 3kW, P3 = 2kW, V = 220V
L1 = 10m; L2 = 16m L3 = 20m;
Mean cos ϕ = 0.8; ∆V = 2.5V

Req: Cross sectional area of conductor A

a) if a uniform x-section of conductor is desired along L3
b) if a uniform voltage drop in each section is desired
c) if sectional voltage drop is in proportion to section currents
Solution: a) Generally, I = P/(1.73 x V x cos ϕ ) and thus
I1 = 2500/(1.73 x 220 x 0.8) = 8.2;
I2 = 3000/(1.73 x 220 x 0.8) = 9.84A;
I3 = 2000/(1.73 x 220 x 0.8) = 6.56A

A = 1.73 x(8.2 x 10 + 9.84 x 16 + 6.56 x 20) x 0.8/ (56 x 2.5) = 3.668 mm2 choose 4 mm2
b)

c)

4.3.1.2 Table reference method

A simpler approach in electrical installation design is to use pre calculated values of voltage drops of the type prepared by the
Institute of Electrical Engineers (IEE). See table for instance

Wire 2 cables single 3 or 4 wires 4 wires 4 wires 4 wires 4 wires

x- core single core twin core three core Four core 7 core
sectio Max Volt Max ∆V/A/ Max ∆V/A/ Max ∆V/A/ Max ∆V/A/ Max 1 2-ph
n curre drop in curre m curre m curre m curre m curre phase ∆V/A/
A[mm nt mV per nt nt nt nt nt ∆V/A/ m
2
] I [A] Amp I [A] [mV] I [A] [mV] I [A] [mV] I [A] [mV] I [A] m
per [mV]
meter [mV]
(∆V/A/
m)
1.0 23 42 20 36 19 42 16 36 16 36 11 42 36
1.5 29 28 26 24 24 28 20 24 20 24 14 28 24
2.5 39 17 34 14 32 17 26 14 27 14 19 17 14
4.0 50 10 44 9 41 10 34 9 35 9 24 10 9
6.0 63 6.9 50 6 53 6.9 44 6 45 6 - - -
10.0 85 4.2 75 3.6 71 4.2 59 3.6 61 3.6 - - -
16.0 110 2.6 99 2.3 94 2.6 78 2.3 81 2.3 - - -
25 150 1.7 130 1.4 124 1.7 105 1.4 110 1.4 - - -
35 180 1.2 160 1.0 - - - - - - - - -
50 225 0.83 200 0.72 - - - - - - - - -
70 275 0.59 240 0.51 - - - - - - - - -
95 330 0.44 290 0.38 - - - - - - - - -
120 380 0.35 335 0.30 - - - - - - - - -
150 440 0.28 385 0.24 - - - - - - - - -

14
 Maximum continuous loading of insulated conductors and coordination of protective devices
(Copper conductors at 25 Deg Celsius ambient temperature)
SN Nominal Group 1: One or more Group 2: Multi-core Group 3: Single-core
cross single conductors in cables cables in air
section of conduit
wire (mm2) Max. Fuse or Max. Fuse or Max. Fuse or
permissible CB permissible CB rating permissible CB rating
continuous rating continuous (A) continuous (A)
loading (A ) (A) loading (A ) loading (A )
1. 0.75 -- -- 13 10 16 16
2. 1.0 12 10 16 16 20 20
3. 1.5 16 16 20 20 25 25
4. 2.5 21 20 27 25 34 35
5. 4.0 27 25 36 35 45 50
6. 6.0 35 35 47 50 57 63
7. 10.0 48 50 65 63 78 80
8. 16.0 65 63 87 80 104 100
9. 25 88 80 115 100 137 125
10. 35 110 100 143 125 168 160
11. 50 140 125 178 160 210 200
12. 70 175 160 220 224 260 250
13. 95 210 200 265 250 310 300
14. 120 250 250 310 300 365 355
15. 150 -- -- 355 355 415 425
16. 185 -- -- 405 355 475 425
17. 240 -- -- 480 425 560 500
18. 300 -- -- 555 500 645 600
19. 400 -- -- -- -- 770 710
20. 500 -- -- -- -- 880 850
21. 630

Table 3: Standard 4-conductor cables in mm2

No. of conductors x size No. of conductors x No. of conductors x No. of conductors x
(mm2) size (mm2) size (mm2) size (mm2)
2
4 x 4 mm 4 x 25 mm2 3 x 70/35 mm2 3 x 185/95 mm2
2
4 x 6 mm 3 x 25/16 mm2 3 x 95/50 mm2 3 x 240/120 mm2
4 x 10 mm2 3 x 35/16 mm2 3 x 120/70 mm2 3 x 300/150 mm2
2
4 x 16 mm 3 x 50/25 mm2 3 x 150/70 mm2 3 x 400/185 mm2

Properties of copper and aluminum

Density Resist- Conduc- Temp. Tensile Elongatio Brinell Meltin Specific Thermal Linear
ivity tivity coef strengt n hardnes g point heat conductiv expansion
h [∆L/L] s ity
cal/(g . mm/m.de
Kg/dm3 .mm2/m S.mm2/m 1/deg kP/mm2 % kP/mm2 O
C deg) cal/(cm.s. g
[ 1 cal = deg)
4.186J]
Copper 8.9 0.00178 56 0.0039 21-24 > 38 40 1084 0.092 0.94 0.017
Or 8900 200 385
kg/m3 N/mm2 J/(kg-
deg)
Aluminu 2.7 0.0303 33 0.0036 7 -10 45 -30 15 -25 658 0.214 0.50 0.023
m
Or 2700 900
kg/m3 J/(kg-
deg)

15
Example1 (previously solved): Each conductor of a copper cable of length 200m has a cross sectional area of 10mm2. The cable
supplies power to a 220V, single phase motor of 5kW rating that works on full load at cos ϕ = 0.87 and efficiency of 87%.

It has been required to determine

a) the supply voltage required b) the power loss in the cable c)the inductance voltage drop at 50Hz

Now compute the voltage drop on the cable if the cable to be used is single core of cross-sectional area of 10 mm2 and if the
voltage drop is higher than previously computed (i.e. 18.27V) then use the next higher cable

Solution :

It has been found that I = 30A;

∆VR = 2IR cos ϕL = 18.27 V [computationally determined)

Using table 2, for two cable single core 10 mm2 we see from table ∆V/A/m = 4.2 mV

The actual voltage drop on the cable becomes

∆VT = I x L x ∆V/A/m = 30A X 200m X 4.2 x 10-3 V/A/m = 25.2 V > 18.27

If we now use the 2 x 16 mm2 cable, its voltage drop ∆V/A/m = 2.6 mV/A/m.
Thus actual voltage drop on this cable becomes,
=> ∆V = 30A x 200m x 2.6 x 10-3 V/A/m = 15.6V < 18.27V

Example 2:

A tannery requires three raw waste transfer pumps of rating 10 HP each driven by a three phase star connected induction motor.
The motors are supplied from a switch board situated 50m away. Determine the size of cable and the automatic circuit breaker
rating required. Assume a 2.5% voltage drop may be tolerated where supply to the motors is 380V line. For each motor cos ϕ is
0.88 and efficiency = 0.88.

Solution:
For each motor, In = P/(1.73 x V x eta x cos ϕ ) = 10 x746/1.73x380x0.88x0.88 = 14.64 A
Type of cable selected = 4 core PVC sheathed
The allowable voltage drop = 2.5% of 380 = (2.5/100) x 380 = 9.5V
From the above table (table 1) we calculate
for 1mm2: max. continuous current rating 16A; ∆V/A/m = 36 mV
∆V = 14.64 x 50 x 36 x 10-3 = 26.35V > 9.5V (not good enough)

for 1.5 mm2: rating 20A; ∆V/A/m = 24 mV

∆V = 14.64 x 50 x 24 x 10-3 = 17.5 V > 9.5V (not good enough)

for 2.5 mm2: rating 27A; ∆V/A/m = 14 mV

∆V = 14.64 x 50 x 14 x 10-3 = 10.2 V > 9.5V (still not good enough)

for 4 mm2: rating 35A; ∆V/A/m = 9 mV

∆V = 14.64 x 50 x 9 x 10-3 = 6.6 V < 9.5V

Thus we take 4 x 6 mm2

Note: As far as the current rating is concerned even the 1 mm2 conductor is sufficient ! However, the deciding factor is the
voltage drop.

According to the table from EEPCO

16
 for a cable enclosed in a conduit for 4 mm2 ∆V = 5.3V
for an unenclosed cable ∆V = 5.1 V

Therefore 4 x 4 mm2 serves the purpose.

Note: the table provided by EEPCO and that by IEE (1966, reprinted in 1970) have, more or less the same data.

In most cases, there will be a number of sub-mains from the electrical intake of the building to distribution fuse boards, and from
each of these there will be a number of final circuits. The allowable voltage drop is the sum of the drops in the sub-mains and in
the final circuits, and there is no restriction on how it is shared between the two. The position of each distribution board will
affect the lengths both of sub-mains and of final circuits and thus of the voltage drop in each of them.

There is no single correct way in which these parameters must be combined, and the design can only be done by a process of trial
and error tempered by the designer’s own experience and judgment. There is plenty of scope for a designer to exercise his
personal initiative and intuition in positioning distribution boards and selecting cable sizes to arrive at an economical design. In
general, it is a better all-round solution to take the final distribution board as near to the current, using equipment as possible,
thus reducing the length of the final circuits to a minimum.

4.3.2 Cable size selection accounting increased ambient temperature

If a cable is installed in an ambient temperature of 25°C and loaded with the maximum rated current, the final temperature will
be 70°C. Then, if the cable is installed at a temperature above 25°C, the starting temperature of the cable will be higher, and the
running temperature will also be higher. Therefore, to prevent the cable from overheating, we must make adjustments to the
current carrying capacity of the cable, if it is installed in an ambient temperature above 25°C.

For rubber insulated conductor the maximum admissible heating up is assumed to be reached with a temperature rise of 35OC so
that the limit temperature is fixed at 25OC + 35OC = 60OC.
Thermoplastics insulating materials permit an excess temperature of 45OC giving a limit of 70OC.
For instance, for a general purpose PVC at 35°C the correction factor is 0.94. This means that the cable may only be loaded to 94
per cent of its 30°C capacity.

Table values of current capacities are provided for a room temperature of 25OC and less.
Typical table below relates to temperature correction factor (Ca) for ambient temperature.

Room temp OC 30 35 40 45 50 55 60
Temperature correction 0.92 0.85 0.75 0.65 0.53 0.38 0.30
factor for value in table, Ca

Example: A 1 kW electric appliance is to be supplied from a 220V from a single phase source 200m away. Assume an allowed
2.5% voltage drop and max operating temperature of a rubber insulated copper conductor cable to be 45 OC. Determine the
appropriate cross sectional area of copper wire to be used to satisfy the constraints.

Solution:

From current capacity point of view, I = P/V = 1000/220 = 4.5 A. And for this we read from table a size of 1.0 mm2 (which has
a max. permissible continuous loading capacity of 12A at 250C) is quite sufficient.

At a temperature of 45 OC, the current carrying capacity of the conductor reduces to 65%, i.e. it would carry 0.65 x 12 A = 7.8 A.
This is still sufficient.

From voltage drop consideration, the cross section should be at 25OC, A (mm2) 200 x P x L / σCV2
Or A = 200 x 1000 x 200/(57 x 2.5 x 2202 ) = 5.8 mm2

17
Since σ (T) = 1/ (T) =1/ 25(1 + ∆T) => σ (T) = σ 25/(1 + ∆T) = 57/[1 + 0.0039 (Tf – 25)]

Thus at T = 45OC, σ (T) = 57/[1 + 0.0039 (45 – 25)] = 52.87 S m/mm2

And at 45OC, A = 200 x 1000 x 200/(52.87 x 2.5 x 2202 ) = 6.25 mm2

Thus choice of cable = [(A >= 1.0 mm2) (A >= 6.25 mm2)] => A = 6.25 mm2 we thus choose the next higher size, i.e A =
10 mm2

4.3.3 Cable size selection accounting number of conductors

If circuits were grouped with other circuits or if multicore cables were bunched with other multicores in an enclosure, the heat
dissipation properties of the circuits or cables would be reduced. The more cables there are in the group, the dissipation
properties of the cable are reduced. Then if the cables were loaded to their ungrouped level, when they are grouped they would
overheat. The number of grouped circuits must therefore be taken into account. Tables should be referred for correction factors
Cg to account for grouping.

For instance, for two enclosed multicore cables bunched and clipped direct to a non-metallic surface, Cg = 0.80. This means that
for two circuits, only 80 per cent of the single circuit current is allowed. For three circuits, Cg = 0.70. This means that for three
circuits, only 70 per cent of the single circuit or multicore current is allowed. If a cable is grouped with three other circuits (4 in
total), Cg = 0.65.

No. of multicore groups, or multiple circuit 1 2 3 4

group
Grouping correction factor, Cg 1 0.8 0.7 0.65

Thus, if the current rating of one of the cables in non-grouped condition is Iz, then the new current capacity when grouped with
other cables will reduce to I/z = Cg x Iz

If, in addition ambient temperature change is encountered for the bunched cables, the combined correction factor of grouping and
temperature will be C = Cg x Ca. This means that the current capacities of each of the cables is reduced by a factor of C, i.e. I/z
= C x Iz..

If the cable is run in heat-insulating material, its ability to dissipate heat will be impaired. To take this into consideration, a heat
insulation correction factor Ci is applied to the length of the cable enclosed in thermal insulation.

Thus, the combined effects of ambient temperature change, grouping, and heat insulation utilization will result a combined
correction factor C = Cg x Ca x Ci and I/z = C x Iz.

4.3.4 Cable size selection accounting protective device & correction factors

The protective device current rating In should be greater than the design current Ib. of the circuit/ appliance. That is, In Ib and
its value is selected from standard tables.

For the protective device to protect the cable against overload, the minimum cable rating, Iz = In or Iz In.

Under normal condition (25OC, un-grouped, and with no heat insulation), the tabulated rated value of the cable Iz = It I n.

When one or all correction factors are to be accounted, we use them as divisor/s to determine the corrected rating of the cable as

I/z = Min. It In/(Cg×Ca×Ci)

18
 When a re-wireable fuse is to be used, a factor of 0.725 is used in addition. The formula is now amended to I/z = Min. It
In/(Cg×Ca×Ci x 0.725)
If any of the factors are not applicable, ignore them or replace with a 1.

Example

The figure below represents one single-phase thermoplastic 70°C circuit enclosed in conduit. The design current Ib = 45A. The
corresponding minimum fuse size chosen from BS88 range of fuses is 50A. For the fuse to protect the cable against overload, the
minimum cable rating, Iz, is 50A. Also, the minimum tabulated rating, It, for the cable is also 50A. If the cable is grouped with
three other circuits (4 in total), Cg = 0.65.

Therefore the minimum rating Iz, or the minimum tabulated rating It of the cable will be
Iz = It In/Cg = 50/0.65=76.92A

Figure: Device rating related to design current and grouping cables

In other words a cable which will carry 76.92A is acceptable, but the cable must be derated to a factor of 0.65: 76.92×0.65=50

Therefore, in these conditions, the cable is rated at 50A. We are selecting a larger size of cable because of the reduction in
current carrying capacity due to grouping. However, the fuse rating remains 50A.

If the above circuit is run further at a temp of 35OC, there are two correction factors to apply, one for grouping and one for
ambient temperature above 30°C. The minimum rating of the cable will be
Iz= It In/Cg×Ca=50/(0.94×0.65)=81.83A

Example 3
Single-phase 240V, 36A loads are to be supplied by means of 70°C thermoplastic PVC twin and earth cables having copper
conductors, 25m in length, in an area having an ambient temperature of 35°C (Ca= 0.94). The cables are touching and single-
layer clipped to a non-metallic surface (for 3 circuits Cg=0.79). The overcurrent device at the origin of the installation is a type-B
MCB to BS EN 60898. Calculate the minimum permissible cable size.

Solution: Method 1
Design current Ib =36A. Nominal rating of the device (from table) In=40A ( Ib), Cg=0.79, Ca=0.94.
Thus, tabulated rating of cable Iz = It In/Cg x Ca = 40/0.79 x 0.94 =53.86A

Consulting manufacturer’s appropriate table, It = 64A. Therefore, the minimum size with respect to current carrying capacity is
10mm2.

A, mm2 Multicore cable, Max.

permissible continuous
loading (A )
1.0 16
1.5 20
2.5 27
4.0 36
6.0 47
10.0 65
16.0 87

19
If the volt drop does not exceed 4% of the nominal voltage of the mains, ∆V = 240 x 0.04 = 9.6V

We now need to check that the voltage drop in the 10mm2 cable is within these limits. Table for the cable gives voltage drop in
millivolts per ampere per meter of 4.4. To calculate the voltage drop, multiply mV/Amp/m x Ib x Meters/1000. Thus ∆V = 4.4 x
36 x 25/1000 = 3.96V < 9.6V.

We see therefore, the minimum permissible size is 10mm2.

If the circuit was protected by a rewireable fuse to BS 3036, the design of the circuit would be slightly different.

Method 2

Design current Ib=36A. Nominal rating of the device In = 45A (a rewireable fuse to BS 3036); Cg=0.79, Ca=0.97.
Thus Iz = It In/Cg x Ca x 0.725 = 45/0.555=81A

Consulting manufacturer’s appropriate table, It = 85A. Therefore, the minimum size with respect to current carrying capacity is
16mm2.

The voltage drop ∆V = mV/Amp/m x Ib x Meters/1000 = 2.8 x 36 x 25/1000 = 2.252V < 9.6V.
Therefore, the minimum permissible size is 16mm2. Note that semi-enclosed fuses should be rigorously avoided these days. BS
7671 expresses a preference for cartridge-type fuses.

4.3.5 Summarized Cable Size Selection Procedure for Constant Load or Final circuits

i. Determine design current, Ib, based on continuous load of cable.

a. Single phase

for single phase continuous load PL, V is phase voltage and
is power factor angle.
b. Three phase

for three phase load PL, VL is line voltage and
is power factor angle.

ii. Select cable type for desired application (for over head, underground, indoor, outdoor, wet, dry etc) based on
a. Type of insulation like PVC, Rubber, Mineral, XLPE etc.
b. Conductor type like copper or aluminum
c. Number of cores like single core, multiple core,

iii. Apply correction factors for ambient temperature, grouping, and heat insulation if any.

If over current protection is to be used,

Corresponding to the design current Ib select from standard tables the rating of the protection device In (Note: In Ib ) and the
minimum current carrying capacity of cable Iz = It to be selected will then be

20
For semi-enclosed fuses (i.e. rewireable fuse) divide further by 0.725.
i.e. It In/(Cg×Ca×Ci x 0.725)

If over current protection is not to be provided for the circuit, select the minimum current carrying capacity of cable, It, to
be selected as

where Ca, Cg, and Ci are ambient temperature, group, and insulation correction factors.

iv. Check for the allowable voltage drop using the continuous current in the cable (that is the design current).

If the computed voltage drop is higher than the allowed, choose the higher cross-section until the voltage drop is in the allowed
range.

4.4 Protection and Control Device Selection (Study section 9 of EBCS-10)

Short Circuit calculation

In electrical installation design, short circuit calculation is required to select the protective devices, i.e. circuit breakers and fuses.
The maximum breaking capacity of the circuit breaker or fuse to be selected for the circuit has to be greater than the prospective
short circuit current (PSCC). PSCC is the short-circuit current that would arise if the short circuit were replaced by an ideal
connection having negligible impedance with out alteration of the incoming supply [1].

Worked Example 1.

An industrial premises is supplied through a transformer 15/0.4kV, 75 KVA, and 4.75% per unit impedance. Refer to Fig. 1.
Determine the prospective short circuit currents if three-phase to ground short-circuit occurs at points A, B, C and D as shown in
the figure. The cable used is PVC insulated non-armored three core copper with the following size and lengths.
from transformer to main distribution center (MDC) 120 mm2 with 10 meters length,
from BDC to SDB1, 25 mm2 and 50 meters,
from SDB1 to SDB11 16 mm2 and 25 meters.

a) Calculate the prospective short circuit currents at points A, B, C, and D.

b) Select appropriate circuit breakers CB1, CB2, CB3 and CB4.
c) Select appropriate fuse if fuses are to be used in place of CB1, CB2, CB3 and CB4.

Solution:

The prospective short circuit current is the balanced three-phase to ground short circuit current.

The phase-to-phase to ground and single phase to ground short-circuit currents are normally smaller than the three-phase to
ground short-circuit current.

To determine the three-phase to ground short-circuit current let us first determine the transformer impedance.

Per unit base values per phase:

21
Volt-ampere per phase =75/3=25kVA
Current = 25,000/231 =108A
Impedance Z= 231/108 = 2.14 

Per unit impedance 4.75% means the transformer impedance is (2.14 4.75)/100 =0.10165
 

Fig. 1 Power supply to an industrial premises

The three-phase-to-ground short circuit current at point A can then be calculated as 231/0.10165 = 2.272kA

For short circuit at point B, the impedance is the transformer impedance plus the cable impedance. The cable of 120 mm2 has
resistivity of 0.43 mili-Ohm per meter (EBCS-10). That means for the 10 meter length it is 4.3 mili-Ohm.

Thus, the prospective short circuit current at point B is approximately equal to that of A. Only bus-bar whose cross sectional area
is high is between A and B.

The short-circuit current at point C can be calculated as follows:

For short circuit at point D, the impedance is transformer impedance plus the total cable impedance.
The 10 meter cable of 120 mm2 and 50 meters of 25 mm2. The cable of 25 mm2 has resistivity of 1.85 mili-Ohm per meter
(EBCS-10). That means for the 50 meter length it is 92.5 mili-Ohm.
The prospective short circuit current at point D is then

Thus at A ( and also B) the breaking capacity IbA of CB1 should be >= PSCCA , i.e , IbA > 2.272kA
At C the breaking capacity IbC of CB2 should be >= PSCCC , i.e , IbC > 2.180 kA
At D the breaking capacity IbD of CB3 should be >= PSCCD , i.e , IbD > 1.164 kA
22
4.5. Fuse/CB selection schemes

Fuse manufacturers furnish information on time-current characteristics and peak let-through charts
for each fuse.

Use of the time-current characteristics

Example of Time-Current Characteristic curves is given in Fig. 1, below.

Example: An electric motor has 24A rating current. Its inrush current is 100A. For over current protection of 125% (i.e. 1.25 x
24 = 30A) check if the 30A fuse can hold the inrush current.

Solution:
At 100A draw horizontal line to intersect the 30A fuse curve. Then draw vertical line down to the base line. It can be seen that
the fuse fuses at 40sec for a current of 100A. Since the motor takes normally well below 40 sec to start, the fuse can be used to
protect the over current condition.

If a fault of 500A occurs, however, the fuse can clear the fault in about 0.02 sec. i.e. before the motor starts!

Fig. Typical Current-time curve of fuses

Peak let through current charts

Peak let-through currents or energy are given for cables, equipments, devices, etc. That is each equipment has ability to
withstand a certain amount of electric energy for a given time before the equipment is damaged.

Example: Consider a molded case circuit breakers (MCCB)

Given: - Interrupting rating of circuit breakers 10,000 A rms.


Available short-circuit current at the panel 40,000 A rms.



Fuse protecting the panel has 100 A.

Check if the fuse can protect the panel from damage incase of the short circuit current.

Solution:
Find the 40,000 A on the horizontal axis and draw a vertical line until it intersects the 100A fuse line.
Draw a horizontal line from the intersection point until intersection with line A-B and move vertically down to the horizontal
axis. Read the 4600A which means that the fuse permits an apparent let-through current of 4600A rms when subjected to
40000A.

23
Hence, the fuse can protect a 10000A interrupting capacity against 40000 A rms fault current.

Fig. Typical Peak let-through chart for fuse

The Short circuit current

Fig. Short circuit current

Consider Fig. 3, short-circuit current at time = 0 and Ip is the available short circuit current peak if there is no protection. If there
is protection, the fuse melts at time tm, and during arcing ta, the fault is cleared. The area shaded squared represents the melting
and arcing areas the total energy to which the circuit is subjected. If the circuit is not protected by current limiting fuse the circuit
will be subjected to the area under the Ip curve squared.

The current limiting fuse is required to limit the let-through current and I2t to the withstand rating of the equipment it is to
protect. Note that the energy during the short circuit is not only of heat energy but magnetic force proportional to Ip2.

24
If the over current protection device at the origin of the circuit is for short-circuit protection only, as would be the case for a
motor circuit, then the following formula stated in BS 7671 section 434–03 is employed:

where t = time taken to reach the limit temperature

K= is a factor taken from table 43A BS 7671
S = cross sectional area in mm2
I = fault current.

Example: A motor circuit is supplied by means of 4mm2 thermoplastic 70°C PVC copper cables. The protection device at the
origin of the circuit is a 50A fuse with prospective short circuit current of 300A. The K value for thermoplastic 70°C PVC
copper cables is 115. The time for the cable to reach its limit temperature is

To take a typical BS 88 fuse, 300A, flowing through a 50A fuse would disconnect in about 1.2 sec. Therefore, the fuse would
operate before the cable reached its limit temperature, the cable being protected against short circuit. Because of the cable
resistance, 10m along the run the short-circuit current will be attenuated to 263A, giving a time to reach the limit temperature of
above 3s. The disconnection time would, however, increase to about 2.5s. The cable is still protected.

Mention should also be made of the circuit protective conductor. The function of this is described in Chapter 9. Under normal
conditions it carries no current and it conducts electricity only when an earth fault occurs and, then, only for the short time before
the protective device operates. BS 7671 gives two alternative ways of determining its size. The first is by the use of the same
formula as above, transposed to make S the subject of the formula, as has been quoted above, for checking the short circuit rating
of the live conductor. Alternatively, the regulations give a table which relates the size of the protective conductor to the size of
the phase conductor. The effect is that for circuits up to 16mm2, the protective conductor minimum size must be equal to the line
or phase conductor, for 25mm2 and 35mm2 phase conductors, the protective conductor must be at least 16 mm2, and for phase
conductors over 35 mm2 the cross section of the protective conductor must be at least half the cross section of the phase
conductor.

25
Exercise
Suppose the following distribution system and load is given.

a) Determine the size of each cable conductor in the sections between the SDB and the load assuming ambient temperature and
the power is single phase.
b) If a short circuit occurs at the main distribution box bus, determine
i) the breaking capacity of the circuit breaker CB1 if only CB1, CB2 and CB3 are closed/connected and all other branch
circuits are open.

26
4.6 Cable size (& protective device capacity) selection for Variable or Distribution Centers

In the practice of cable size and protective device capacity selection for a branch circuit, a feeder line, and a service entrance,
we usually study for economic reason as well as feasibility the level of electric power that a particular line actually carries on
an average level as well as the duration of service.

It is known that all connected loads to a distribution center may not function simultaneously. For example, a residential
building service cable may have to supply the lighting system, socket outlets and air conditioners. Experience tells us that we
don’t switch on all lighting in our residential building at the same time. While the family is in living room the lighting in the
bed rooms are normally off. In order to select cable size there are rules of thumb for different applications which are available
on standards.

i) Demand factor and diversity factor method

As already stated, in many cases it is unlikely that all the appliances connected to a branch circuit, and hence to feeder cables
and service entrance feeder cable will be switched on all at the same time. Thus the maximum current that the respective
conductors will carry will be less than the total permissible current which would flow if all the appliances were switched on
simultaneously.

A factor that accounts this reduction in the current and hence the actual power demand are the demand factor (DmF) and the
diversity factor(DvF). Their values are between zero and one or between 0 and 100%.

Demand factor is the ratio of the maximum demand of the system (or part of the system i.e. branch)
to the total connected load on the system, or
to the maximum demand of the whole system, or
part of the system, under consideration [EBCS-10 pp150 to 156].

Demand factor of the system (or sub system i.e branch) =

Maximum demand of a branch/ total actual connected load of the branch

The total power demand can be calculated from the data relative to the location and power of each load, together with the
knowledge of the operating modes (steady state demand, starting conditions, non simultaneous operation, etc.)

The maximum demand of a consumer is the maximum (peak) load a consumer draws for some minutes usually about 15
minutes or more. The maximum demand can be determined by the total connected load in the consumer premises and
knowledge of their operating schedule or demand factor.

That is
Max. demand of a sys or sub sys (branch) =

Demand factor of the sys or sub sys X Max. demand of a branch/ total actual connected load of the branch

Thus, the maximum demand power at a distribution center (such as SDB) or at the service entrance (MDB) is calculated
using the total actually connected load at the SDB or at the MDB accounting a demand factor knowledge based on experience
and/or from standard tables.

Accordingly, the power required from the supply source and (where appropriate) the number of sources necessary for an
adequate supply to the installation are readily obtained.

Continuous load: any condition in which the maximum load current in a circuit flows without interruption for a period of
not less than 3.0 hrs.

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Other terms include :

Diversity factor:
has an important place in the design of an installation and its final costing. IEE regulation 311-01 deals
with the subject.
is applied to sub main and main cables and their associated gears/ circuit breakers to reduce the cross
sectional area of the cable conductor, and the capacity of the switch gears/ circuit breakers.
The factor is based on the assumption that the whole of the connected load will not be turned on at the
same time. For example, the total lighting load in a dwelling house is rarely switched on at a time during
the life of the installation.
There are ten types of final circuit fed from wiring to which diversity applies: lighting, heating,
cooking appliances which are permanently connected, motors (other than lifting motors), instantaneous
type water heater, thermostatically controlled water heater, floor-warming installation, thermal-storage
space-heating installation, 13A fused socket outlets and appliance fed there from, and other socket
outlets such as 15A sockets.
A factor for diversity shall not be allowed for calculating the size of circuit conductor and switchgears of
final sub circuits, other than specified circuits such as cooker circuits. It is noted that the provision of an
allowance for diversity is a matter of calling for a special knowledge and experience. Indeed, the
application of the diversity should be decided by the engineer responsible for designing each particular
installation. The amount by which they are increased or decreased for each installation is a matter for the
installation engineer to decide.
Is mathematically defined as the ratio of the sum of the individual maximum demands of the various subdivisions of
a system, or part of a system, to the maximum demand of the whole system, or part of a system, under consideration.

Example
Purpose of wiring Applied D.F. (%)
Lighting sub circuit
Domestic 50 -60
Hotel 75
Shops 90
Heating and power appliances 100 for max current up to 10A
Motors 100 for the largest motor
50 for the remaining

ii) Method of operation schedule knowledge of connected loads

In this method, estimation of maximum load is determined based on the knowledge of operation schedule of the connected
loads which are all assumed known.

For example a pump station may have six pumps driven by six induction motors supplied from the bus-bar fed by a cable. If
it is known that four of the pumps operate normally while one is standby and the other one is under repair, the design has to
be based on the rating current of the four induction motors. The cable feeding the bus-bar thus is selected in such a way that it
can carry the load current of the four induction motors.

iii) Premises total area method

In this method, the design rating for a particular application in a premises depends on the total area of the particular area of
the premises. According to EBCS-10, recommended power per unit area of the different parts of a premises such as schools,
hospitals, stores, etc. is estimated and provided in table. Refer to EBCS-10 Section 6 pp 150 to 156.

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4.7. Typical cable and protection device selection for common appliances refer to (EBCS ….)

This method is based on empirical observations of many factors and

4.7.1 Socket outlets

1. Up to 8 sockets outlets can be fed by a feeder of cable size not less than 2.5mm2 protected by fuse of 15A, if the socket
outlets are to serve less than 30m2 area, but not kitchen.

2. If the area is above 30 m2 and cable is 2.5mm2, the number of socket outlets connected to a feeder has to be 4 or less with
15A protection fuse.

But, if the cable size is increased to 4 mm2 with a protection fuse of 25A, the number of socket outlets can be up to 8 for
area more than 30m2.

3. Maximum number of socket outlets on one feeder when the load is not known exactly is limited to 12.
If the load to be connected to the sockets is exactly known the feeder cable and its protection can be selected based on
the maximum continuous current.

4. If the socket outlet is for a particular portable appliance of rating more than 1500W, it has to be fed through a separately
controlled and protected dedicated feeder.

The feeder cable size and protection device should be determined based on the appliances continuous current rating.

4.7.2 Lighting Points

1. Lighting points can be connected in parallel to the same feeder if the total current in the feeder is less than 15A and
protected by a 16A fuse.

2. If the power of lighting point is not known exactly, a 100W can be assumed per lamp holder for the feeder total current
calculation.

4.7.3 Heating and general electric appliances

Any appliance with power rating of more than 1500W has to be fed by a dedicated cable with its own control and protection

4.7.4. Electric Motor Installation

Electric motors, though prevalent for industrial applications, can also be part of the appliances in commercial and even
residential premises.

Electric motors can be of continuous duty, intermittent duty or short time duty.

Individual electric motors feeder circuits.

The following six steps can be used for the installation of electrical motors.
1. Determining the motor full load current. The maximum demand for the circuit depends on the duty of motor. For the
continuous time duty 125% of the motor rating current is taken as the maximum demand current.
For intermittent and short time duties standard tables have to be used. For example refer to table below from EBCS-10.
2. Determine the size of the motor branch circuit conductor
3. Determine the fuse size (dual element) to be used as motor branch-circuit short circuit and ground fault protection.
4. Determine the rating requirement for the motor disconnecting switch.
5. Determine the motor and branch circuit overload protection requirement

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6. Determine the requirement for the motor control circuit over current protection

Table Conductor size for motors for different service requirement (EBCS-10 Table 11.2 pp271)
Classification of Application areas % of nameplate current of motor
service
5 minute 15 minutes 30 and 60 Continuous rating
rating rating minutes rating

Short time duty Operating valves, 110 120 150 --

raising or lowering
rollers, etc.
Intermittent duty elevators, pumps, rolls, 85 90 95 140
ore and coal-handling
machines

Varying duty 110 120 150 200

From the table it can be seen that the short time duty motor cable size is relatively large compared to the intermittent. This is
because motors for short time duty generally operate overloaded.

Example:
It is desired to design and installs a squirrel cage induction electric motor fed from a 380V bus-bar. The electric motor
nameplate values are Pn= 2.2 kW, nn=2850 rpm, Vn=380V, pf=0.8. The motor is for continuous duty operation.

Solution:

Step 1.
The full load current of the motor can be obtained from the following equation. Note that this equation assumes the motor
efficiency to be 100%. If the efficiency is to be considered the motor current would be slightly higher. There are some data
books providing the full load current corresponding to motor power and voltage ratings.

= 5.22 A
Step 2.
Assuming no correction factors for ambient and group, etc. the minimum ampacity of conductor to be
used according to standards is 125% of the motor full load.

Iz = 5.22 x 1.25 = 6.54 A

The corresponding size for particular cable to be used checked from table.

Table I: Single core PVC insulated copper conductor with sheath, current carrying capacity and voltage drop.

Example: from the following table 1 mm2 can be used.

Step 3: Short circuit protection fuses

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Is to be greater than the full load current 16 A can be chosen. Maximum setting or rating of short circuit and ground fault
protection devices is given below according to NEC.
Step4: Determining the rating requirement for disconnecting switch.

Standards guide the designer the minimum rating of the disconnect switch. American NEC for example requires 115% of full
load current.

Minimum rating of disconnect switch =1.115 x 4.2 =5.3

From Table we can choose 16A.

Table: Maximum rating or setting of motor Branch circuit short-circuit and ground fault protective devices

Step 5: Overload protections for motor and branch circuit.

The branch circuit overload protection is for cable protection. While the motor overload protection is to protect the motor
itself. The motor brunch circuit protection is located at the distribution board where the feeder starts. Its rating 125% of full
load current is usually the rating of overload protection devices. Standards or regulations may give other requirements or
flexibilities.

The motor protection is usually provided by bimetal thermal relay and is included with the motor control. Current rating of
over current relay to respond to motor overloading is also of the above rating (125% full load).

Overload for motor

Figure below demonstrates typical electric motor feeder circuit for a three-phase induction motor. It is fed from a distribution
board with circuit breaker provided with protection for short circuit and over current. The feeder cable feeds the power to the
motor via switch used as means of isolation and magnetic contactor for control provided with thermal over load (OL)
protection.

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 Fig. Typical induction motor and control circuit
Step six:
The control circuit of the motor may require protection because it may extend to remote start/stop button.
If the control cable is of small size the impedance associated is normally high. Therefore; the branch circuit protection device
may not clear any fault on the control circuit. Relevant regulations can be consulted for decision.

The control circuit must be protected from;

1. earth which leads to fire hazard
2. earth which prevents the motor disconnection
3. earth which leads an intended switching on of the motor

Table 11.2 Conductor size for motors for different service requirement

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From the table it can be seen that the short time duty motor cable size is relatively large compared to the intermittent. This is
because motors for short time duty generally operate overloaded.

For the continuous duty tables like 11.5 can be used for protection fuse and circuit breaker selection.

OL : OverLoad; OC : Over Current; TD: Time Delay; NTD; Non Time Delay
Each motor of fixed installation and of high rating (greater than 1/3hp) has also to be provided with motor starter or
controller for starting and stopping. The contactor may not disconnect earth line unless it is used as means of isolation.

For the continuous duty tables like 11.5 can be used for protection fuse and circuit breaker selection.
Each motor of fixed installation and of high rating (greater than 1/3hp) has also has to be provided with motor starter or
controller for starting and stopping. The contactor may not disconnect earth line unless it is used as means of isolation.

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