3.

Electrical installation design of a consumer

3.1. 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.

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

1
 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 correction apparatuses to optimize their energy utilization cost.

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.

2
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.

Fig. Typical sub-station for medium or high voltage supplied consumer

3.2. 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.

3
Figure a) Only from MDB to SDB b) from MDB to SDB and from SDB to SDB

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.
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,

4
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

3.3. 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.

5
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.

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 cable
Electric power cables
etc

3.3.1. Cable size selection accounting voltage drop calculation

3.3.1.1 Using pure analytical method (without table reference)

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

6
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
∆V 2IR = 2IL/σ σA

or

A (mm2) σ∆V
2IL(m)/σ …….. 3.1

If ∆V is in percentage of the rated value [i.e (∆V/V)100% = C 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 …….. 3.2

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.

7
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
the component Vs sin δ so that

Vs = VL + IR cos ϕL + IX sin ϕL

|∆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

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
8
 a) the sending side voltage required
b) the power loss in the cable
c) the inductance voltage drop at 50Hz

Solution:
σA, Rph = 200/ (57 x 10) = 0.35 Ω
Resistance of the conductor of the cable pair, R = L/σ
The current in each conductor, I = P/( VLcos ϕL ) = 5000/(0.87 x 220 x 0.87) = 30 A
a) Vs = Vr + ∆VR = where ∆VR = 2IR cos ϕL = 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) 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

Thus 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

Reactive power in the cable would be Q = 2I2X = 2 x 302 x 0.1 H/km x 0.2km = 36 var

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.

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 )

9
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%

10
3.3.1.1.2 Cable size calculation with voltage drop in unbranched three phase wires

General ac load (reactive + resistive)

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 I2R

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 V2)

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

= [3 RI2/ (1.73 V I cos ϕ)] x 100
= 173 RI/ ( V cos ϕ)

11
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.

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 consumers of different power factors are connected in parallel 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.

If multiple three phase loads are connected at a single point, the total current can be approximated from
I = ( Pin)/1.73 x V x cos ϕ

3.3.1.1.3 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
12
 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
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

13
 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/(σ 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

∆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

14
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

3.3.1.1.4 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

15
 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

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

Solution: Ans. I1 ≈ 10A; I2 ≈ 12A; I3 ≈ 8A;

I = P/(1.73 x V x cos ϕ )
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

3.3.1.2 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 x- 2 cables single core 3 or 4 wires 4 wires 4 wires 4 wires 4 wires
section single core twin core three core Four core 7 core
A[mm2] Max Volt drop Max ∆V/A/m Max ∆V/A/m Max ∆V/A/m Max ∆V/A/m Max 1 phase 2-ph
current in mV current current current current current ∆V/A/m ∆V/A/m
I [A] per Amp I [A] [mV] I [A] [mV] I [A] [mV] I [A] [mV] I [A]
per meter [mV] [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 - - - - - - - - -

16
 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 No. of conductors No. of conductors
(mm2) x size (mm2) x size (mm2) x size (mm2)
4 x 4 mm2 4 x 25 mm2 3 x 70/35 mm2 3 x 185/95 mm2
4 x 6 mm2 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
4 x 16 mm2 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)

17
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%.
Determine
a) the supply voltage required b) the power loss in the cable c)the inductance voltage drop at 50Hz

Solution :
It has been found that I = 30A; ∆VR = 2IR cos ϕL = 18.27 V
Using table 2, consider two cable single core 10 mm2.

We see ∆V/A/m = 4.2 mV

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

According to EEPCOs regulation, for an enclosed cable, ∆V/A/m = 5V/50m/40A = 2.85 mV/A/m
=> ∆V = 30 x 200 x 2.85 x 10-3 = 16.8V < 18.27V
The conclusion may be that the tables over design. This is because, the tables do not consider power
factor and no phasor additions.

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 = 10 x746/1.73x380x0.88x0.88 = 14.64 A
Type of cable selected = 4 core PVC sheathed
The allowable voltage drop = (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 10A; ∆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

18
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

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.

3.3.2 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 0.92 0.85 0.75 0.65 0.53 0.38 0.30
correction factor for
value in table, Ca
19
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

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 A (45OC) = 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

3.3.3 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 1 2 3 4

circuit group
Grouping correction factor, Cg 1 0.8 0.7 0.65

20
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.

3.3.4 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
In.

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 or I/z = It In/Cg×Ca×Ci

When a rewireable 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 or I/z = It In/Cg×Ca×Ci x 0.725

If any of the factors are not applicable, ignore them or replace with a 1.

Example

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

21
 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.

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.

22
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.

3.3.5 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 and 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

23
For semi-enclosed fuses (i.e. rewireable fuse) divide further by 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 voltage drop is higher than the allowed, choose the higher cross-section until the voltage drop is
in the allowed range.

3.4 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 protection devices;
circuit breakers and fuses. The maximum current breaking capacity of the circuit breaker or fuse to
be selected for the circuit has to be greater than the prospective short circuit current. Prospective
short-circuit current is the short-circuit current that would arise in 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. Two

24
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:

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 (2.144.75)/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.

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 the A and B.
25
The short-circuit current at point C can be calculated as follows:

For short circuit at point C, 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 C is then

3.5. 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% 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 current of 100A. Since the motor takes normally well
below 40 sec to start the fuse can be used to protect the OC. If a fault of 500A occurs the fuse can clear
the fault in about 0.02 sec.

Fig. Typical Current-time curve of fuses

26
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 40000 A on the horizontal axis and draw a vertical line until it intersects the 100A fuse line.
Draw 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.
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

27
 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.

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.
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.

28
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.

Example

Suppose a single phase, 220V socket outlet branch circuit delivers power to eight loads of average value
500 W. Assume that the branch circuit feeder cable is made of copper with rubber insulation, is straight
and has a total length of 50m. Each of the 8 socket sub circuits branch with equal spacing of 5m at the
last section of the feeder cable. Assume each socket outlet sub circuit has a length of 7m of a pair of
conductor of size 1.5mm2 cross section from the feeder cable to the outlet.

The overall allowed voltage drop should be less than 5% and the ambient temperature of the space in
which the cable laid is 30OC. Determine
b) the cross sectional area of the required cable which is assumed uniform.
c) the percentage loss of power in the cable ( Hint: use the effective length and total currents or
losses on individual sections)
c) minimum and maximum short circuit current if the short circuits occurs only in a single socket
outlet sub circuit and in which case all other outlets are assumed open/not being utilized.
d) If the conductor is not to be heated to a temperature of the 160OC, what is the maximum fault
clearing time of the circuit breaker or fuse? [ For copper density = 8900 kg/m3, specific heat
capacity 385J/kg-deg]

Solution:
2 × ( I 1 L 1 + I 2 L 2 + I 3 L 3 ) cos ϕ
a) A = mm2
σ × ∆V
Here cos ph = 1; and each socket current is identical, i.e Ii = P/V = 500W/220 = 2.27A
Allowed voltage drop V = C V/100 = 5 x 220/100 = 0.05 x 220 = 11V

Thus A = 2 x I Li /( V) =
= 2 x 2.27 x [50 + 45 + 40 + 35 + 30 + 25 + 20 + 15]/(56 x 11) = 1.9 mm2

29
 => choose 2.5 mm2

b) PL = 2I2R/PT

R = Lm/( A)
I1 × L1 + I 2 × L 2 + I 3 × L3
Lm = m is the average or effective length of cable
I1 + I 2 + I 3
Lm = I Li/IT = [50 + 45 + 40 + 35 + 30 + 25 + 20 + 15] x I / 8I = 260/8 = 32.5m
Thus R = Lm/( A) = 32.5/(56 x 2.5) = 0.23 ohm

Total power = 8 x 500 = 4000W;

Total carried current = 8 x 500/220 = 18.18 A

PL = 2I2R/PT = 2 x (18.18)2 x 0.23/4000 = 0.038 = 3.8%

Loss with individual sections considered PL = 2(I12R1 + I22R2+ I32R3 + … + I82R8 )/PT
….
c) i) The minimum short circuit current will occur for the extreme end outlet when a short occurs at
its tip. Under this condition we have a 50m pair conductor of 2.5mm2 x-section extended with a 7 m
pair conductor of 1.5 mm2 x-section.

Thus the total resistance offered by this combination becomes RT = R1 + R2

Where at room temperature (16 to 25 OC)
R1 = 2L1/( A1) = 2 x 50/(56 x 2.5) = 0.71 ohm and
R2 = 2L2/( A2) = 2 x 7/(56 x 1.5) = 0.17 ohm

Thus RT = 0.71 + 0.17 = 0.88 ohm

Ignoring change in resistance due to heating, Iscmin = V/ RT = 220/0.88 = 250A = 0.25 kA

ii) The maximum short circuit current will occur for the first outlet when a short occurs at its
junction with the feeder cable. Under this condition we have only a 15m pair conductor of 2.5mm2
x-section.
Thus the total resistance offered by this feeder cable section becomes
RT = 2L/( A) = 2 x 15/(56 x 2.5) = 0.21 ohm
=> Iscmax = V/ RT = 220/0.21 = 1026.7A = 1.027 kA

Thus we should choose a circuit breaker or fuse of breaker capacity Ib > 1.027 kA

d) I2RTt = QCu + QRb = mcuccu T + mrbcrb T

Assuming 70% of the developed heat is carried by the copper conductor,
=> t = mcuccu (Tf – Tamb)/0.7x I2RT
Tf = 160 OC, Tamb = 16 OC => T = 144 OC

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i) For the least short circuit current Iscmin =250A, the mass of the cable
mcu = density x volume = 8900kg/m2 x [2 x 50m x 2.5 + 2 x 7 x 1.5 ] x 10-6 m2 = 2.41 kg

Therefore, t = mcuccu (Tf – Tamb)/0.7xI2RT = [2.41 kg x 385 J/(kg-deg)] x 144 OC /0.7x 2502 x 0.88
= 3.47 sec
i.e the CB should clear the fault before 3.47 sec

Assuming 30% of the developed heat is carried by the insulation of the conductor,
=> t = mrbcrb (Tf – Tamb)/0.3x I2RT

For hard rubber, density = 1.3 kg/dm3; C = 1.68 J/gm-OC = 1680 J/kg- OC
Wall thickness of rubber tubing = 1mm; internal radius = sqrt(A/pi) = sqrt(2.5/3.14) = 0.89mm

Vrb = L*Pi [r2ext - r2int ] = 2 x [50 + 7] x 3.14 x [0.992 - 0.892] x 10-6= 67.33 x10-6 m3

mrb = density x volume = 1300kg/m3 x 67.33 x10-6 m3 = 0.0875 kg

Thus, t = mrbcrb (Tf – Tamb)/0.3x I2RT

= 0.0875 kg x 1680 J/kg- OC x 144 OC /(0.3 x 2502 x 0.88) = 1.283 sec

ii) For the largest short circuit current Iscmax = 1.027 kA, the mass of the cable
mcu = density x volume = 8900kg/m3 x 2 x 15m x 2.5 x 10-6 m2 = 0.6675 kg

Therefore, t = mcuccu (Tf – Tamb)/0.7x I2RT = 0.6675 kg x 385 J/(kg-deg) x 144 OC /(0.7 x 10272 x 0.21)
= 0.239 sec or 239 ms
[For clearing before the conductor melts,
t = mcuccu (Tf – Tamb)/0.7x I2RT
= 0.6675 kg x 385 J/(kg-deg) x (1084 -16)OC /(0.7 x 10272 x 0.21)
= 1.77 sec !! ]

For the rubber insulator,

Vrb = L*Pi [r2ext - r2int ] = 2 x 15 x 3.14 x [0.992 - 0.892] x 10-6= 17.72 x10-6 m3
mrb = 1300kg/m3 x 17.72 x10-6 m3 = 0.023 kg
t = mrbcrb (Tf – Tamb)/0.3x I2RT
= 0.023 kg x 1680 J/kg- OC x 144 OC /(0.3 x 10272 x 0.21) = 0.0839 sec = 83.86 ms
Thus the fault should be cleared before min [239 ms, 83.86 ms] = 83.86 ms

Specification
Maximum continuous loading of copper conductors at 25OC (Group 1: insulated one or more single
copper conductors in conduit) and coordination of protective devices is as follows:
A = 2.5 mm2 ;
Max. permissible continuous loading (A ) = 21A; (> IT=18.18 A)

Corresponding fuse or CB rating (A) = 20A; Breaking capacity of CB > 1.027 kA, say 1.2 kA

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Exercise
Suppose the following distribution system is given.

a) Determine the size of each cable conductor in the sections between the SDB and the load assuming
ambient temperature 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.

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3.6 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) =

33
 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.

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

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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.

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

This method is based on empirical observations of many factors and

3.7.1 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.

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3.7.2 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.

3.7.3 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

3.7.4. Electric Motor Installation

Electric motors, though prevalent for industrial applications, can also 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
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 minutes rating 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

36
 Classification of Application areas % of nameplate current of motor
service
5 minute 15 minutes 30 and 60 Continuous
rating rating minutes rating rating
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 it is 1 mm2 can be used.

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Step 3: Short circuit protection fuses

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 demonstrates typical electric motor feeder circuit for a three-phase induction motor. It is fed
from 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 OL protection.
38
 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

39
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.

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.

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.

40