Sizing Conductors

Sizing of Conductors
Sizing of conductors / Lee CW
Current rating of Cable

The current rating of a cable is determined
by a number of factors, namely
Ambient temperature
Maximum allowable conductor temperature
Conductor material
Insulation material
Installation methods
2
Tabulated current carrying capacities ( It )

It is difficult to determine directly the likely operating
temperature of a range of cables in practice. The
designer relies therefore, on the tabulated current
carrying capacities ( It)
These tabulated values are based upon a given set of
conditions :
ambient temperature of 300C
heating effect of adjacent cables is not considered
cable is installed in a way that corresponds to the rating table
being used
there is no surrounding thermal insulation.
When any of these conditions changed, the cable rating

has to be adjusted accordingly.
Factors affecting the current carrying

capacity (ccc) of cables
Ambient Temperature
Grouping
Thermal Insulation
Other Frequencies
Ambient Temperature
Tabulated ccc usually assumes ambient
temperature at 30oC
therefore at other ambient
temperatures, tabulated ccc need to be
modified
Tables of Correction Factors for
ambient temperatures (Ca) are used
Tables 4C1 and 4C2
6
Grouping
CCC of cables are affected when they
are grouped together in the same
enclosure
correction factor (Cg) is provided by
Table 4B
Thermal Insulation
The tables for ccc has provision for cable in
thermally insulated wall or ceiling but in contact
with a thermally conductive surface on one side
for cables likely to be totally enclosed in thermal
insulation, the ccc is taken as 0.5 times ccc for
that cable clipped direct to a surface and open
(Reference Method 1)
11
Other Frequencies
50 Hz used on land
400 Hz used in planes, result in smaller size
motors (weight reduction)
however ccc of cables may also be reduced by
50% in large multi-core cables
12
Sizing Cables
Protection of cable against overcurrent
overload
short circuit
Overload current - circuit is healthy (sound) but

cable is carrying current above its rated capacity
Short circuit current - circuit short resulting in
extremely large current flow
13
Protection against Overload Current

The relationship between the design current, nominal
rating of the protective device (In ) and current carrying
capacity of the conductor (I2 ) must be achieved
Ib In IZ
I 2 1.45I Z
Ib In Iz
3kW
14
Protective Device characteristics

In = nominal current rating of protective device
e.g. MCB 32A, Fuse 15A
this means that In can flow through the protective
device continuously (in time) without causing
operation of device
I2 = tripping or fusing current - current causing
effective operation of protective device)
this can be up to maximum of 1.5 In and will cause the
protective device to operate within 1 hour (overload
protection)
15
Test
Type
Test
Current
Initial
Condition
B, C,
D
1.13 IN
Cold*
t > 1 h (for IN < 63 A)

t > 2 h (for IN > 63 A)
No
tripping
B, C,
D
1.45 IN
Right after
Test 1
t < 1 h (for IN < 63 A)

t < 2 h (for IN > 63 A)
Tripping
B, C,
D
2.55 IN
Cold *
1 s < t < 60 s (IN < 32 A)

1 s < t < 120 s (IN > 32 A)
Tripping
3 IN
No
tripping
5 IN
t > 0.1 s
(i.e. Instantaneous tripping
does not occur)
10 IN
5 IN
10 IN
50 IN
Cold *
Cold *
Test Period
t < 0.1 s
(i.e. Instantaneous tripping
occurs)
Result
Tripping
16
Protection against Overload Current

(Simplified Approach)
For MCB or fuse protection other than BS3036;
I z = I t CaC g Ci
Since
In IZ
I n I t CaC g Ci
It
In
C aC g Ci
Eqn (i)
For fuse protection by BS3036 only

I 2 1 .45 I Z and
fusing factor(FF) = 2
I 2 = FF I n = 2 I n
2 I n 1.45I
1.45
In
I or 0.725I z or 0 .725 I t C a C g C i
2 z
It
It
Eqn (ii)
0 .725 C a C g C i
17
Protection against short circuit current only

(Simplified Approach)
For cases where protection against overload current is
taken care of by overload relays, eg in motor circuits, the
sizing of the circuit against short circuit current shall be
done is accordance to the eqn below :
Ib
It
Eqn (iii)
CaC g Ci
18
Procedure in determining the minimum

conductor cross-sectional area
Determine the design current of the circuit
Establish the expected ambient temperature, installation
method, grouping and whether circuit is thermally insulated
Obtain the correction factors for respective Tables
Check if circuit is to be protected against short circuit and
overload current
Select the appropriate circuit breaker
Check if voltage drop is acceptable
Check if short circuit protection is afforded
19
Selection of Correction factors

In general,
Protective Protection
Device
provided
1
1 1 1
It I x

C a C g Ci C d
Ix
Ca
from
Cg
from
Cd
Semi enclosed Short circuit

fuse
& overload
In
Table 4C2
Table 4B1
0.725
Short circuit
only
Ib
Table 4C1
Table 4B1
Short circuit
& overload
In
Table 4C1
Table 4B1
Short circuit
only
Ib
Table 4C1
Table 4B1
HBC fuses
(BS88)/
BS1361 or
MCBs
20
Example on the calculation of

design current, Ib
Ib = design current of circuit or load current,
e.g. for water heater of 3kW at 230V,
the design current = 3000W / 230V
= 13.04A
P = VI(cos) i.e. I = P/V(cos)
21
Example on the calculation of

design current, Ib
A 50hp, 400V three phase motor operating at

full load, pf =0.88, efficiency =0.95
Pin
therefore Ib
= 3 x VI(cos)
= Pout/ Pin
= Pout/ (3 x V(cos) )
= 50 x 746/(3 x 400 x 0.88 x 0.95)
= 64.4A
22
Special case Grouped circuits not

liable to simultaneous overload
For circuits, NOT protected by fuse (BS3036);
Calculate I t from the following eqns and
choose the bigger value :
Ib
It
C aC g Ci
1
It
C aCi
I n2 + 0.48 I b2
(i )
( 1 C g2 )
C
2
g
( ii )
23
Special case Grouped circuits not

liable to simultaneous overload
For circuits protected by fuse (BS3036);
Calculate the I t from the following eqns and
choose the bigger value :
Ib
It =
C aC g Ci
I t = 1 .9 I n2 + 0 .48 I b2
(i )
( 1 C g2 )
C
2
g
( ii )
24
Example 1
A heater rated at 230 V, 3 kW is to be installed using twinwith-earth pvc-insulated and sheathed cable clipped direct in
a roof space that has an ambient temperature of 400C. The
circuit is protected by a 15-A MCB. The cable is bundled with
four other twin-and-earth cables for a short distance as shown
below. Determine the minimum tabulated current rating of the
circuit and the size of the conductor.
MCB
15A
40 C
15m, clipped direct
bundled with four

other circuits
3 kW
Heater
25
Solution to Example 1
The design current is :
3000
Ib =
= 13 A
230
The current rating of the protective device (IN ) is 15 A. From Table

4C1, at 400C:
Ca = 0.87
From Table 4B1, grouping factor of five circuits :
Cg = 0.6
The minimum tabulated current rating It for the circuit is :
In
15
It
=
= 28.74 A
Ca C g 0.87 0.6
From Table 4D2A, column 6, a 4 mm2 cable which has a tabulated
current rating of 36 A is selected.
26
(if circuit is not liable to simultaneous overload)
The design current is :
3000
Ib =
= 13 A
230
The current rating of the protective device (In ) is 15 A.

From Table 4C1, at 400C: Ca = 0.87
From Table 4B1, 5 cct,
Cg = 0.6
The minimum tabulated current rating It for the circuit is:
27
(if circuit is not liable to simultaneous overload)
It
Ib
13
=
= 24.9 A
Ca C g Ci 0.87 0.6
It
C a Ci
(i )
2
(
1
C
g )
2
I n2 + 0.48 I b
C g2
2
1
(
1
0
.
6
)
2
2
15 + 0.48 13
0 .6 2
0.87
22.1 A
( ii )
Since eqn (i) > eqn (ii), hence choose

It
24.9 A
From Table 4D2A, column 6, a 2.5 mm2 cable which has a

tabulated current rating of 36 A is selected.
28
Example 2
Determine the minimum tabulated current rating of a multicore, pvc-insulated cable connected to a 3-phase motor rated at
400 V, 15 kW, 0.8 power factor and 90% efficiency. This
motor is subjected to frequent start/stop and is operating at an
ambient temperature of 350C as shown below.
MCB
35C
4C /Cu/PVC, trunking
15kW
0.8 p.f.
90% Eff.
29
The design current is
15 1000
= 30.07 A
Ib =
0.8 0.9 3 400
For frequent start/stop, it is suggested that the minimum circuit

rating be selected from 1.25 to 1.4 of IB. Assume the higher value
of 1.4 and thus the minimum tabulated circuit rating is 1.4 x
30.07 = 42.10 A. To incorporate temperature correction, the
minimum tabulated circuit rating is :
It
42.10
0.94
= 44.79
From Table 4D2A, column 5, a 10 mm2 4-core cable which has

30
a tabulated current rating of 46 A is selected.
Example 3
Q: The circuit is the same as that for Example 1, except that the
cable has to pass through a thermal insulation area over a
length of 3 m. Determine the minimum tabulated current
rating of the circuit and the size of conductor.
S: The minimum tabulated current rating for the circuit is :
IN
15
It
=
= 57.47 A
Ca Cg Ci 0.87 0.6 0.5
From Table 4D2A, column 6, a twin-core cable of 10 mm2

which has a tabulated current of 63 A is selected.
31
32
33
Voltage Drop
Only static voltage drop considered
Equipment will not function properly if incorrect
voltage is being supplied
e.g motors - at 10% being rated voltage output
power (torque) drop by 20%
What is maximum allowable voltage drop?
34
Maximum allowable voltage drop

Measure from origin of circuit to any other
point in the circuit 4% of nominal voltage
Single phase (230V)
Vp (permissible voltage drop 230 x 0.04 = 9.2V
Three phase (400V)

Vp (permissible voltage drop 400 x 0.04 = 16V
35
Tabulated Voltage Drop (TVD) Constant

For cables having conductors of 16 mm2 and lower, as the
values of reactance are very much less than the values of
resistance, the inductance can be ignored, and only the
values of (TVD)r are tabulated.
For cables having conductors greater than 16 mm2, the
impedance values (TVD)z are tabulated together with the
resistive component (TVD r and the reactive component
(TVD)x.
The values of (TVD)r and (TVD)x are twice the value of
the per-phase cable resistance and reactance respectively
36
Tabulated Voltage Drop Constant, TVD

(single-phase)
IR = 50A
1.4m x 100 meters

7V
Load
230V
216 V
7V
The voltage drop in the single-phase circuit shown in the

Figure can be written as :
Vdrop =
=
=
=
IR (1.4 m x 100 + 1.4 m x 100)

IR (1.4 m x 2) x 100
IR (2.8 m) x 100
IR x TVD x 100
38
Conversion of single and

three phase volt drop
To convert from single phase voltage drop
TVD to 3 phase values multiply by 0.866
(or 3 )
2
To convert from three phase voltage drop
TVD to single phase values multiply by
1.155(or 23 )
40
Voltage drop consideration (cont)

In practice, voltage drop calculation is not necessary for final
circuits of a domestic installation if route length is 25m
However for mains and submains, the calculation is
recommended
For circuits using conductors of 16mm2 or less:
TVD I b l
Vd =
volts
( simple approach)
1000
For circuits using conductors of 25mm2 or more:
Vd =
(TVD ) z I b l
1000
volts
( simple approach)
Where TVD= volt drop in mV/A/m

Ib = design current or maximum demand current
l = route length in metres
41
Temperature Correction on Resistive

Value
The value of resistance of a conductor is usually given
at a conductor temperature of 700C in the standards or
by cable manufacturers.
If the temperature of the conductor increases due to the
load current, the value of resistance will also increase
according to the resistance-temperature coefficient.
This coefficient is approximately equal to 0.004 per
00C at 700C for both copper and aluminium conductors.
42
Temperature Correction on Resistive Value

The resistance at 500C can thus be calculated as:
230 + 50
= 70 0.93
230 +70
50 = 70
At 200C, the resistance

temperature coefficient
is 0.004 per 0C
0
0.004/ C
20
70
95
115
160
-230 -200
-100
0 20
70 95 115
160
43
Correction for Conductor Operating Temperature
(for ambient temperature 300C but < 700C and not for fuse (BS3036)
For cables having conductors of cross-sectional area of 16mm2 or less,

the design value of TVD = TVD x Ct , where Ct is:
2
I
b
230 + t p ( Ca2C g2
30 )
2 )( t p
It
ct =
230 + t p
where t p = max imum permitted normal operating temp (700C).
For cables > 16mm2; only resistive component is affected by
temperature, hence,
TVDz = Ct .TVDr + TVDx

For very large cables, resistive component of voltage drop << reactive
44
part, hence, this correction factor can be ignored.
Correction for load power factor

For cables having conductors of cross-sectional
area of 16mm2 or less, the:
design value of TVD = TVD cos
area greater than 16mm2, the:
design value of TVD = TVDr cos + TVDx sin
45
Correction for both Operating Temperature

and Load Power Factor
area of 16mm2 or less, the:
design value of TVD = TVD . Ct . cos
area greater than 16mm2, the:
design value of TVD
= TVDr . Ct . cos + TVDx sin
46
Voltage Drop Formulae

General voltage drop formula :
Vd = I (R cos + X sin)
Voltage drop formula for cables of 16mm2 of less :
((TVD)
.Ct . cos ) I B length

Vd =
1000
Voltage drop formula for cables of greater than 16mm2:
Vd =
((TVD)
.Ct . cos + TVDx . sin ) I B length

1000
47
Example 4
A 3-phase motor with a full load current of 102 A,
and a power factor of 0.8 is to be fed by four singlecore, pvc-insulated, copper conductor, non-armoured
cables, clipped direct on a non-metallic surface at 75metre run as shown below. Determine the size of
conductor if the permissible voltage drop from the
MCB to the motor terminal is 2%.
MCB
IFL = 102A
75m
4 x 1C / Cu/PVC, clipped direct
0.8 p.f.
48
Let the design current Ib be the motors full load current. From Table
4D1A, column 7, a 25 mm2 cable with a current rating of 104 A is
initially selected, and the line-to-line voltage drop is calculated as :
(assume Ct = 1) V = (( TVD )r cos + ( TVD ) sin ) I B length
d
1000
(1.5 0.8 + 0.175 0.6 ) 10275
=
1000
= 9.983 V or 2.496% of 400 V
The calculated Vd is 2.496% exceeds 2% of 400 V. Thus, the next

higher size of 35 mm2 is selected and Vd is re-calculated :
Vd =
(1.1 0.8 + 0.17 0.6 ) 10275
1000
= 7.512 V or 1.88%
This calculated voltage drop is 1.88% of 400 V and thus, a 35 mm2 49

cable is recommended
Example 5
Q:A single-phase circuit is wired in two-core armoured 25mm2
copper conductor XLPE insulated cable. If Ib = 120A and
length = 30m, what is the voltage drop if the power factor is
0.7 lagging?
S: From the Table 4E2B, column 3,
TVDr = 1.85 mV/A/m, TVDx = 0.16 mV/A/m, TVDz = 1.90 mV/A/m
cos = 0. 7, sin = (1 0.7) 0.5 = 0.714
Vd = ((1.85 x 0.7 + 0.16 x 0.714) x 120 x 30)/1000 = 5.07 V
If power factor has been ignored,
Vd = (1.90 x 120 x 30)/1000 = 6.84V
If oltage drop is limited to 2.5% for this circuit, this would be resulted in
a larger cable, ie 35mm2 , being specified.
50
Multi core XPLE copper conductor cables
Example 6
A single-phase circuit having Ib = 27A is run in single-core
700C PVC insulated non-sheathed non-armoured copper
conductor cables. It is enclosed in conduit on a wall with
five other similar circuits. It is protected against both
overload and short circuit by means of a 30A MCB.
If ta = 400C, length = 40m and the power factor = 0.8
lagging, what is the minimum conductor cross-sectional
area that can be used and what is the voltage drop?
52
From Table 4B1, Cg = 0.57
From Table 4C1, Ca = 0.87, and Ci = 1
It In / Ca Cg = 30/(0.57 x 0.87) = 60.5A
From Table 4D1A, column 4,
choose 16mm2 cable which has an It of 76A.
From Table 4D1B, column 3, TVD = 2.8 mV/A/m.
53
Solution to Example 6 (cont)

230+t p ((C a2C g2
Ct
I b2
2 )(tt 30 )
It
230+t p
230+70 ( 0.87 20.57 2
Vd
27 2
30 )
2 )( 70
76
230 + 70
300 ( 0.25 0.12 )( 40 )
=
= 0.98
300
((TVD)r .Ct .cos ) I B length
=
1000
( 2.8 0.98 0.8 27 40 )
=
1000
= 2.37V
54
Protection against short circuit current
To verify that the short circuit currents will be

interrupted quickly before they can cause a
dangerously high temperature rise in the circuit
conductors:
k S I t
2
2
f
55
Short circuit requirement

During short circuiting, very heavy current
flows through the cable in a very short
duration.
A very large amount of energy is let through =
I2t
This current raises the temperature of the cable
in a very short duration of time.
57
Short circuit requirement (cont)

Cable will be damage if the protective device
protecting the circuit does not cut-off the short
circuit fast enough.
Cable will not suffer any permanent damage if the
thermal capacity of cable let through energy of
short circuit.
Thermal capacity = k2S2
k = factor taking into account of properties of cable
material and initial and final temperature
s = cross-sectional area of conductor
58
Example 7
A 10 mm2 PVC insulated copper cable is short-circuited
when connected to a 230 V supply. The impedance of the
short circuit path is 0.1 . Calculate the maximum
permissible disconnection time and show that 50 A type 2
MCB to BS 3871 will meet this requirement
V
=
Z
230
=
0 .1
= 2300 A
59
For copper conductor and PVC insulation, Table 43A gives
a value for of 115. So
115 2 10 2
=
= 0.25s
2
2300
The maximum time that a 2300 A fault current can be

applied to this 10 mm2 cable without dangerously raising the
conductor temperature is 0.25 sec. Therefore, the
protective device must disconnect supply to the cable in
less than this time under short circuit conditions. The actual
tripping time of the MCB is only 0.01 sec. Hence, the circuit
is protected.
60
Adiabatic curve of Fuse compared to

conductor being protected
61
Adiabatic curve of MCB compared to

conductor being protected
62
Formulae for short circuit currents

Three-phase Fault. For 3-phase fault, the current
magnitude in each phase is identical except that the
angle is shifted by 1200 in each phase.
I F,3 =
VLL
(R S + R1 )2 + (X S + X1 )2
where RS and XS are the per-phase values of the resistance and

reactance of the supply source; R1 and X1 are the per-phase
values of the resistance and reactance of the phase conductor and
VLL is the line-to-line voltage.
63
Formula for short circuit currents (cont)

Line-to Neutral Fault.
I F, LN =
VLL
(R S + R1 + R n )2 + (X S + X1 +
X n )2
where Rn and Xn are the values of resistance

and reactance of the neutral conductor.
64
Formula for short circuit currents (cont)

Line-to-Line Fault. For a line-to-line fault, if the effect of
the healthy phase is neglected
I F, LL =
VLL
(2R S + 2 R1 )2 + (2X S + 2 X1 )2
The values of the source resistance RS and reactance XS

should be obtained from the supply utility or can be
estimated from the impedance of the incoming
transformer. The phase conductors resistance, R1 and
reactance, X1, can be referred to the tabulated voltage
drop constant, TVD.
65
Adiabatic curve of FUSE compared to

conductor for various short circuit currents
66
Adiabatic curve of MCB compared to

conductor for various short circuit currents
67

Sizing Conductors

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Sizing Conductors

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Sizing of Conductors

Sizing of conductors / Lee CW

Current rating of Cable

Sizing of conductors / Lee CW

Tabulated current carrying capacities ( It )

When any of these conditions changed, the cable rating

Sizing of conductors / Lee CW

Factors affecting the current carrying

Sizing of conductors / Lee CW

Sizing of conductors / Lee CW

Sizing of conductors / Lee CW

Sizing of conductors / Lee CW

Sizing of conductors / Lee CW

Overload current - circuit is healthy (sound) but

Sizing of conductors / Lee CW

Protection against Overload Current

Sizing of conductors / Lee CW

Protective Device characteristics

Sizing of conductors / Lee CW

t > 1 h (for IN < 63 A)

t < 1 h (for IN < 63 A)

1 s < t < 60 s (IN < 32 A)

Sizing of conductors / Lee CW

Protection against Overload Current

For fuse protection by BS3036 only

Sizing of conductors / Lee CW

Protection against short circuit current only

Sizing of conductors / Lee CW

Procedure in determining the minimum

Sizing of conductors / Lee CW

Selection of Correction factors

Semi enclosed Short circuit

Sizing of conductors / Lee CW

Example on the calculation of

Sizing of conductors / Lee CW

Example on the calculation of

A 50hp, 400V three phase motor operating at

Sizing of conductors / Lee CW

Special case Grouped circuits not

Sizing of conductors / Lee CW

Special case Grouped circuits not

Sizing of conductors / Lee CW

bundled with four

Sizing of conductors / Lee CW

The current rating of the protective device (IN ) is 15 A. From Table

Sizing of conductors / Lee CW

The current rating of the protective device (In ) is 15 A.

Sizing of conductors / Lee CW

Since eqn (i) > eqn (ii), hence choose

From Table 4D2A, column 6, a 2.5 mm2 cable which has a

Sizing of conductors / Lee CW

Sizing of conductors / Lee CW

For frequent start/stop, it is suggested that the minimum circuit

From Table 4D2A, column 5, a 10 mm2 4-core cable which has

Sizing of conductors / Lee CW

From Table 4D2A, column 6, a twin-core cable of 10 mm2

Sizing of conductors / Lee CW

Sizing of conductors / Lee CW

Sizing of conductors / Lee CW

What is maximum allowable voltage drop?

Sizing of conductors / Lee CW

Maximum allowable voltage drop