Electrical installation handbook

Volume 2 Electrical devices

nd
2 edition

1SDC010001D0202

Electrical devices
02/04
1SDC010001D0202
Printed in Italy

Due to possible developments of standards as well as of

materials, the characteristics and dimensions specified in
this document may only be considered binding after
confirmation by ABB SACE.

ABB SACE S.p.A.

An ABB Group Copany
L.V. Breakers
Via Baioni, 35
24123 Bergamo - Italy ABB SACE
Tel.: +39 035.395.111 - Telefax: +39 035.395.306-433
http://www.abb.com
Electrical devices
Electrical installation handbook

Volume 2

Electrical devices

2nd edition
February 2004
 First edition 2003
Second edition 2004

Published by ABB SACE

via Baioni, 35 - 24123 Bergamo (Italy)

All rights reserved

 Index

Introduction .............................................................................................. 2

1 Standards
1.1 General aspects .............................................................................. 3
1.2 IEC Standards for electrical installation .......................................... 15
2 Protection of feeders
2.1 Introduction ................................................................................... 22
2.2 Installation and dimensioning of cables ......................................... 25
2.2.1 Current carrying capacity and methods of installation .......... 25
Installation not buried in the ground ..................................... 31
Installation in ground ............................................................ 44
2.2.2 Voltage drop ........................................................................ 55
2.2.3 Joule-effect losses ............................................................... 66
2.3 Protection against overload ........................................................... 67
2.4 Protection against short-circuit ...................................................... 70
2.5 Neutral and protective conductors ................................................ 78
2.6 Busbar trunking systems ............................................................... 86
3 Protection of electrical equipment
3.1 Protection and switching of lighting circuits ................................. 101
3.2 Protection and switching of generators ....................................... 110
3.3 Protection and switching of motors ............................................. 115
3.4 Protection and switching of transformers .................................... 131
4 Power factor correction
4.1 General aspects .......................................................................... 146
4.2 Power factor correction method .................................................. 152
4.3 Circuit-breakers for the protection and
swiching of capacitor banks ........................................................ 159
5 Protection of human beings
5.1 General aspects: effects of current on human beings .................. 162
5.2 Distribution systems .................................................................... 165
5.3 Protection against both direct and indirect contact ...................... 168
5.4 TT system ................................................................................... 171
5.5 TN system .................................................................................. 174
5.6 IT system .................................................................................... 177
5.7 Residual current devices ............................................................. 179
5.8 Maximum protected length for the protection of human beings ... 182
Annex A: Calculation tools
A.1 Slide rules ............................................................................. 200
A.2 DOCWin ............................................................................... 205
Annex B: Calculation of load current Ib .............................................. 209
Annex C: Calculation of short-circuit current ................................... 213
Annex D: Calculation of the coefficient k for the cables .................. 227
Annex E: Main physical quantities and
electro technical formulas .................................................. 230

ABB SACE - Electrical devices 1

 Introduction
Scope and objectives
The scope of this electrical installation handbook is to provide the designer and
user of electrical plants with a quick reference, immediate-use working tool.
This is not intended to be a theoretical document, nor a technical catalogue,
but, in addition to the latter, aims to be of help in the correct definition of
equipment, in numerous practical installation situations.

The dimensioning of an electrical plant requires knowledge of different factors

relating to, for example, installation utilities, the electrical conductors and other
components; this knowledge leads the design engineer to consult numerous
documents and technical catalogues. This electrical installation handbook,
however, aims to supply, in a single document, tables for the quick definition of
the main parameters of the components of an electrical plant and for the selection
of the protection devices for a wide range of installations. Some application
examples are included to aid comprehension of the selection tables.

Electrical installation handbook users

The electrical installation handbook is a tool which is suitable for all those who
are interested in electrical plants: useful for installers and maintenance technicians
through brief yet important electrotechnical references, and for sales engineers
through quick reference selection tables.

Validity of the electrical installation handbook

Some tables show approximate values due to the generalization of the selection
process, for example those regarding the constructional characteristics of
electrical machinery. In every case, where possible, correction factors are given
for actual conditions which may differ from the assumed ones. The tables are
always drawn up conservatively, in favour of safety; for more accurate
calculations, the use of DOCWin software is recommended for the dimensioning
of electrical installations.

2 ABB SACE - Electrical devices

 1 Standards

1.1 General aspects

In each technical field, and in particular in the electrical sector, a condition
sufficient (even if not necessary) for the realization of plants according to the
status of the art and a requirement essential to properly meet the demands
of customers and of the community, is the respect of all the relevant laws and
technical standards.
Therefore, a precise knowledge of the standards is the fundamental premise
for a correct approach to the problems of the electrical plants which shall be
designed in order to guarantee that acceptable safety level which is never
absolute.

Juridical Standards
These are all the standards from which derive rules of behavior for the juridical
persons who are under the sovereignty of that State.

Technical Standards
These standards are the whole of the prescriptions on the basis of which
machines, apparatus, materials and the installations should be designed,
manufactured and tested so that efficiency and function safety are ensured.
The technical standards, published by national and international bodies, are
circumstantially drawn up and can have legal force when this is attributed by a
legislative measure.

Application fields
Electrotechnics and Mechanics, Ergonomics
Telecommunications
Electronics and Safety
International Body IEC ITU ISO
European Body CENELEC ETSI CEN
This technical collection takes into consideration only the bodies dealing with electrical and electronic
technologies.

IEC International Electrotechnical Commission

The International Electrotechnical Commission (IEC) was officially founded in
1906, with the aim of securing the international co-operation as regards
standardization and certification in electrical and electronic technologies. This
association is formed by the International Committees of over 40 countries all
over the world.
The IEC publishes international standards, technical guides and reports which
are the bases or, in any case, a reference of utmost importance for any national
and European standardization activity.
IEC Standards are generally issued in two languages: English and French.
In 1991 the IEC has ratified co-operation agreements with CENELEC (European
standardization body), for a common planning of new standardization activities
and for parallel voting on standard drafts.

ABB SACE - Electrical devices 3

 1.1 General aspects

1 Standards
CENELEC European Committee for Electrotechnical Standardization
The European Committee for Electrotechnical Standardization (CENELEC) was
set up in 1973. Presently it comprises 27 countries (Austria, Belgium, Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary,
Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Portugal, Poland, Slovakia, Slovenia, Spain, Sweden, Switzerland, United
Kingdom) and cooperates with 8 affiliates (Albania, Bosnia and Herzegovina,
Bulgaria, Croatia, Cyprus, Romania, Turkey, Ukraine) which have first maintained
the national documents side by side with the CENELEC ones and then replaced
them with the Harmonized Documents (HD). CENELEC hopes and expects
Cyprus to become the 28th members before May 2004.
There is a difference between EN Standards and Harmonization Documents
(HD): while the first ones have to be accepted at any level and without additions
or modifications in the different countries, the second ones can be amended to
meet particular national requirements.
EN Standards are generally issued in three languages: English, French and
German.
From 1991 CENELEC cooperates with the IEC to accelerate the standards
preparation process of International Standards.
CENELEC deals with specific subjects, for which standardization is urgently
required.
When the study of a specific subject has already been started by the IEC, the
European standardization body (CENELEC) can decide to accept or, whenever
necessary, to amend the works already approved by the International
standardization body.

EC DIRECTIVES FOR ELECTRICAL EQUIPMENT

Among its institutional roles, the European Community has the task of
promulgating directives which must be adopted by the different member states
and then transposed into national law.
Once adopted, these directives come into juridical force and become a reference
for manufacturers, installers, and dealers who must fulfill the duties prescribed
by law.
Directives are based on the following principles:
harmonization is limited to essential requirements;
only the products which comply with the essential requirements specified by
the directives can be marketed and put into service;
the harmonized standards, whose reference numbers are published in the
Official Journal of the European Communities and which are transposed into
the national standards, are considered in compliance with the essential
requirements;
the applicability of the harmonized standards or of other technical specifications
is facultative and manufacturers are free to choose other technical solutions
which ensure compliance with the essential requirements;
a manufacturer can choose among the different conformity evaluation proce-
dure provided by the applicable directive.
The scope of each directive is to make manufacturers take all the necessary
steps and measures so that the product does not affect the safety and health

4 ABB SACE - Electrical devices

 1.1 General aspects

1 Standards
of persons, animals and property.
Low Voltage Directive 73/23/CEE 93/68/CEE
The Low Voltage Directive refers to any electrical equipment designed for use
at a rated voltage from 50 to 1000 V for alternating current and from 75 to 1500 V for
direct current.
In particular, it is applicable to any apparatus used for production, conversion,
transmission, distribution and use of electrical power, such as machines,
transformers, devices, measuring instruments, protection devices and wiring
materials.
The following categories are outside the scope of this Directive:
electrical equipment for use in an explosive atmosphere;
electrical equipment for radiology and medical purposes;
electrical parts for goods and passenger lifts;
electrical energy meters;
plugs and socket outlets for domestic use;
electric fence controllers;
radio-electrical interference;
specialized electrical equipment, for use on ships, aircraft or railways, which
complies with the safety provisions drawn up by international bodies in which
the Member States participate.

Directive EMC 89/336/EEC (Electromagnetic Compatibility)

The Directive on electromagnetic compatibility regards all the electrical and
electronic apparatus as well as systems and installations containing electrical
and/or electronic components. In particular, the apparatus covered by this
Directive are divided into the following categories according to their
characteristics:
domestic radio and TV receivers;
industrial manufacturing equipment;
mobile radio equipment;
mobile radio and commercial radio telephone equipment;
medical and scientific apparatus;
information technology equipment (ITE);
domestic appliances and household electronic equipment;
aeronautical and marine radio apparatus;
educational electronic equipment;
telecommunications networks and apparatus;
radio and television broadcast transmitters;
lights and fluorescent lamps.
The apparatus shall be so constructed that:
a) the electromagnetic disturbance it generates does not exceed a level allowing
radio and telecommunications equipment and other apparatus to operate
as intended;
b) the apparatus has an adequate level of intrinsic immunity to electromagnetic
disturbance to enable it to operate as intended.
An apparatus is declared in conformity to the provisions at points a) and b)
when the apparatus complies with the harmonized standards relevant to its
product family or, in case there arent any, with the general standards.

ABB SACE - Electrical devices 5

 1.1 General aspects

1 Standards
CE conformity marking
The CE conformity marking shall indicate conformity to all the obligations
imposed on the manufacturer, as regards his products, by virtue of the European
Community directives providing for the affixing of the CE marking.

When the CE marking is affixed on a product, it represents a declaration of the

manufacturer or of his authorized representative that the product in question
conforms to all the applicable provisions including the conformity assessment
procedures. This prevents the Member States from limiting the marketing and
putting into service of products bearing the CE marking, unless this measure is
justified by the proved non-conformity of the product.

Flow diagram for the conformity assessment procedures established by the Directive
73/23/EEC on electrical equipment designed for use within particular voltage range:

EC declaration of
Technical file conformity
The manufacturer The manufacturer
draw up the technical guarantees and declares
Manufacturer documentation that his products are in

ASDC008045F0201
covering the design, conformity to the technical
manufacture and documentation and to the
operation of the directive requirements
product

Naval type approval

The environmental conditions which characterize the use of circuit breakers for
on-board installations can be different from the service conditions in standard
industrial environments; as a matter of fact, marine applications can require
installation under particular conditions, such as:
- environments characterized by high temperature and humidity, including salt-
mist atmosphere (damp-heat, salt-mist environment);
- on board environments (engine room) where the apparatus operate in the
presence of vibrations characterized by considerable amplitude and duration.

In order to ensure the proper function in such environments, the shipping

registers require that the apparatus has to be tested according to specific type
approval tests, the most significant of which are vibration, dynamic inclination,
humidity and dry-heat tests.

6 ABB SACE - Electrical devices

 1.1 General aspects

1 Standards
ABB SACE circuit-breakers (Isomax-Tmax-Emax) are approved by the following
shipping registers:

RINA Registro Italiano Navale Italian shipping register

DNV Det Norske Veritas Norwegian shipping register
BV Bureau Veritas French shipping register
GL Germanischer Lloyd German shipping register
LRs Lloyds Register of Shipping British shipping register
ABS American Bureau of Shipping American shipping register

It is always advisable to ask ABB SACE as regards the typologies and the
performances of the certified circuit-breakers or to consult the section certificates
in the website http://bol.it.abb.com.

Marks of conformity to the relevant national and

international Standards
The international and national marks of conformity are reported in the following
table, for information only:

COUNTRY Symbol Mark designation Applicability/Organization

EUROPE Mark of compliance with the

harmonized European standards
listed in the ENEC Agreement.

AUSTRALIA AS Mark Electrical and non-electrical

products.
It guarantees compliance with
SAA (Standard Association of
Australia).

AUSTRALIA S.A.A. Mark Standards Association of

Australia (S.A.A.).
The Electricity Authority of New
South Wales Sydney Australia

AUSTRIA Austrian Test Mark Installation equipment and

materials

OVE

ABB SACE - Electrical devices 7

 1.1 General aspects

1 Standards
COUNTRY Symbol Mark designation Applicability/Organization
AUSTRIA VE Identification Cables
Thread

BELGIUM CEBEC Mark Installation materials and electrical

appliances

BELGIUM CEBEC Mark Conduits and ducts, conductors

and flexible cords

BELGIUM Certification of Installation material and electrical

Conformity appliances (in case there are no
equivalent national standards or
criteria)

CANADA CSA Mark Electrical and non-electrical

products.
This mark guarantees compliance
with CSA (Canadian Standard
Association)

CHINA CCEE Mark Great Wall Mark Commission for

Certification of Electrical
Equipment

Czech Republic EZU Mark Electrotechnical Testing Institute

Slovakia Electrotechnical Research and

Republic EVPU Mark Design Institute

8 ABB SACE - Electrical devices

 1.1 General aspects

1 Standards
COUNTRY Symbol Mark designation Applicability/Organization
CROATIA KONKAR Electrical Engineering Institute

DENMARK DEMKO Low voltage materials.

Approval Mark This mark guarantees the
compliance of the product with
the requirements (safety) of the
Heavy Current Regulations

FINLAND Safety Mark Low voltage material.

of the Elektriska This mark guarantees the
Inspektoratet compliance of the product with
the requirements (safety) of the
Heavy Current Regulations

FRANCE ESC Mark Household appliances

FRANCE NF Mark Conductors and cables

Conduits and ducting
Installation materials

FRANCE NF Identification Cables

Thread

FRANCE NF Mark Portable motor-operated tools

FRANCE NF Mark Household appliances

ABB SACE - Electrical devices 9

 1.1 General aspects

1 Standards
COUNTRY Symbol Mark designation Applicability/Organization
GERMANY VDE Mark For appliances and technical
equipment, installation accessories
such as plugs, sockets, fuses,
wires and cables, as well as other
components (capacitors, earthing
systems, lamp holders and
electronic devices)
GERMANY VDE
Identification Thread Cables and cords

GERMANY VDE Cable Mark For cables, insulated cords,

installation conduits and ducts

GERMANY VDE-GS Mark Safety mark for technical equipment

for technical to be affixed after the product has
been tested and certified by the VDE
equipment Test Laboratory in Offenbach; the
geprfte
conformity mark is the mark VDE,
Sicherheit
which is granted both to be used
alone as well as in combination with
the mark GS
HUNGARY Hungarian Institute for Testing and
MEEI Certification of Electrical Equipment

JAPAN JIS Mark Mark which guarantees

compliance with the relevant
Japanese Industrial Standard(s).

IRELAND IIRS Mark Electrical equipment

IRELAND CO N F IIRS Mark Electrical equipment

OF O
R
K

MI
MAR

TY

I . I. R . S .

10 ABB SACE - Electrical devices

 1.1 General aspects

1 Standards
COUNTRY Symbol Mark designation Applicability/Organization

ITALY IMQ Mark Mark to be affixed on electrical

material for non-skilled users; it
certifies compliance with the
European Standard(s).

NORWAY Norwegian Approval Mandatory safety approval for low

Mark voltage material and equipment

NETHERLANDS KEMA-KEUR General for all equipment

KEUR

POLAND KWE Electrical products

B
RUSSIA Certification of Electrical and non-electrical
Conformity products. It guarantees complance
with national standard
(Gosstandard of Russia)

SINGAPORE SISIR Electrical and non-electrical

O
SIN
GAPO
R products
R O V ED T

E
STA N D AR
PP

A D

SLOVENIA SIQ Slovenian Institute of Quality and

Metrology

SPAIN AEE Electrical products.

R M I DA D A The mark is under the control of
FO
C A DE CON

NO

the Asociacin Electrotcnica

R MA S U N

Espaola(Spanish Electrotechnical
Association)
AR

M E

ABB SACE - Electrical devices 11

 1.1 General aspects

1 Standards
COUNTRY Symbol Mark designation Applicability/Organization

SPAIN AENOR Asociacin Espaola de

Normalizacin y Certificacin.
(Spanish Standarization and
Certification Association)

SWEDEN SEMKO Mandatory safety approval for low

Mark voltage material and equipment.

SWITZERLAND Safety Mark Swiss low voltage material subject

to mandatory approval (safety).

SWITZERLAND Cables subject to mandatory

approval

SWITZERLAND SEV Safety Mark Low voltage material subject to

mandatory approval

UNITED ASTA Mark Mark which guarantees

KINGDOM compliance with the relevant
N

TR
IO

AD
AT

British Standards
C

E
FI

M
TI

AR
ER

K
C

UNITED BASEC Mark Mark which guarantees

KINGDOM compliance with the British
Standards for conductors, cables
and ancillary products.

UNITED BASEC Cables

KINGDOM Identification Thread

12 ABB SACE - Electrical devices

 1.1 General aspects

1 Standards
COUNTRY Symbol Mark designation Applicability/Organization

UNITED Compliance with the British

BEAB
KINGDOM Standards for household
Safety Mark
appliances

UNITED BSI Compliance with the British

KINGDOM Safety Mark Standards

B R IT I S
UNITED TO H BEAB Compliance with the relevant
ROVED

ST

KINGDOM Kitemark British Standards regarding

A N D AR

safety and performances

PP

A D

DENT LA B
EN OR
EP
ND

AT
OR
AN I

U.S.A. Electrical and non-electrical

Y

UNDERWRITERS
TES

Y
ET

products
TI

LABORATORIES
AF

G
N

FO S
R P U B L IC

Mark
L I S T E D
(Product Name)
(Control Number)

U.S.A. UNDERWRITERS Electrical and non-electrical

LABORATORIES products
Mark

U.S.A. UL Recognition Electrical and non-electrical

products

CEN CEN Mark Mark issued by the European

Committee for Standardization
(CEN): it guarantees compliance
with the European Standards.

CENELEC Mark Cables

ABB SACE - Electrical devices 13

 1.1 General aspects

1 Standards

COUNTRY Symbol Mark designation Applicability/Organization

CENELEC Certification mark providing

Harmonization Mark assurance that the harmonized
cable complies with the relevant
harmonized CENELEC Standards
identification thread

EC Mark assuring the compliance

Ex EUROPEA Mark with the relevant European
Standards of the products to be
used in environments with
explosion hazards

CEEel Mark which is applicable to some

CEEel Mark household appliances (shavers,
electric clocks, etc).

EC - Declaration of Conformity
The EC Declaration of Conformity is the statement of the manufacturer, who
declares under his own responsibility that all the equipment, procedures or
services refer and comply with specific standards (directives) or other normative
documents.
The EC Declaration of Conformity should contain the following information:
name and address of the manufacturer or by its European representative;
description of the product;
reference to the harmonized standards and directives involved;
any reference to the technical specifications of conformity;
the two last digits of the year of affixing of the CE marking;
identification of the signer.
A copy of the EC Declaration of Conformity shall be kept by the manufacturer
or by his representative together with the technical documentation.

14 ABB SACE - Electrical devices

 1 Standards

1.2 IEC Standards for electrical

installation
STANDARD YEAR TITLE
IEC 60027-1 1992 Letter symbols to be used in electrical
technology - Part 1: General

IEC 60034-1 1999 Rotating electrical machines - Part 1:

Rating and performance
IEC 60617-DB-12M 2001 Graphical symbols for diagrams - 12-
month subscription to online database
comprising parts 2 to 11 of IEC 60617
IEC 61082-1 1991 Preparation of documents used in
electrotechnology - Part 1: General
requirements
IEC 61082-2 1993 Preparation of documents used in
electrotechnology - Part 2: Function-
oriented diagrams
IEC 61082-3 1993 Preparation of documents used in
electrotechnology - Part 3: Connection
diagrams, tables and lists
IEC 61082-4 1996 Preparation of documents used in
electrotechnology - Part 4: Location and
installation documents
IEC 60038 1983 IEC standard voltages
IEC 60664-1 2000 Insulation coordination for equipment
within low-voltage systems - Part 1:
Principles, requirements and tests
IEC 60909-0 2001 Short-circuit currents in three-phase a.c.
systems - Part 0: Calculation of currents
IEC 60865-1 1993 Short-circuit currents - Calculation of
effects - Part 1: Definitions and
calculation methods
IEC 60781 1989 Application guide for calculation of short-
circuit currents in low-voltage radial
systems
IEC 60076-1 2000 Power transformers - Part 1: General
IEC 60076-2 1993 Power transformers - Part 2: Temperature
rise
IEC 60076-3 2000 Power transformers - Part 3: Insulation
levels, dielectric tests and external
clearances in air
IEC 60076-5 2000 Power transformers - Part 5: Ability to
withstand short circuit
IEC/TR 60616 1978 Terminal and tapping markings for power
transformers
IEC 60726 1982 Dry-type power transformers
IEC 60445 1999 Basic and safety principles for man-
machine interface, marking and
identification - Identification of
equipment terminals and of terminations
of certain designated conductors,
including general rules for an
alphanumeric system

ABB SACE - Electrical devices 15

 1.2 IEC standards for electrical installation

1 Standards
STANDARD YEAR TITLE
IEC 60073 1996 Basic and safety principles for man-
machine interface, marking and
identification Coding for indication
devices and actuators
IEC 60446 1999 Basic and safety principles for man-
machine interface, marking and
identification - Identification of
conductors by colours or numerals
IEC 60447 1993 Man-machine-interface (MMI) - Actuating
principles
IEC 60947-1 2001 Low-voltage switchgear and controlgear -
Part 1: General rules
IEC 60947-2 2001 Low-voltage switchgear and controlgear -
Part 2: Circuit-breakers
IEC 60947-3 2001 Low-voltage switchgear and controlgear -
Part 3: Switches, disconnectors, switch-
disconnectors and fuse-combination
units
IEC 60947-4-1 2000 Low-voltage switchgear and controlgear -
Part 4-1: Contactors and motor-starters
Electromechanical contactors and motor-
starters
IEC 60947-4-2 2002 Low-voltage switchgear and controlgear -
Part 4-2: Contactors and motor-starters
AC semiconductor motor controllers and
starters
IEC 60947-4-3 1999 Low-voltage switchgear and controlgear -
Part 4-3: Contactors and motor-starters
AC semiconductor controllers and
contactors for non-motor loads
IEC 60947-5-1 2000 Low-voltage switchgear and controlgear -
Part 5-1: Control circuit devices and
switching elements - Electromechanical
control circuit devices
IEC 60947-5-2 1999 Low-voltage switchgear and controlgear -
Part 5-2: Control circuit devices and
switching elements Proximity switches
IEC 60947-5-3 1999 Low-voltage switchgear and controlgear -
Part 5-3: Control circuit devices and
switching elements Requirements for
proximity devices with defined behaviour
under fault conditions
IEC 60947-5-4 1996 Low-voltage switchgear and controlgear -
Part 5: Control circuit devices and
switching elements Section 4: Method
of assessing the performance of low
energy contacts. Special tests
IEC 60947-5-5 1997 Low-voltage switchgear and controlgear -
Part 5-5: Control circuit devices and
switching elements - Electrical
emergency stop device with mechanical
latching function

16 ABB SACE - Electrical devices

 1.2 IEC standards for electrical installation

1 Standards
STANDARD YEAR TITLE
IEC 60947-5-6 1999 Low-voltage switchgear and controlgear -
Part 5-6: Control circuit devices and
switching elements DC interface for
proximity sensors and switching
amplifiers (NAMUR)
IEC 60947-6-1 1998 Low-voltage switchgear and controlgear -
Part 6-1: Multiple function equipment
Automatic transfer switching equipment

IEC 60947-6-2 1999 Low-voltage switchgear and controlgear -

Part 6-2: Multiple function equipment -
Control and protective switching devices
(or equipment) (CPS)
IEC 60947-7-1 1999 Low-voltage switchgear and controlgear -
Part 7: Ancillary equipment - Section 1:
Terminal blocks
IEC 60947-7-2 1995 Low-voltage switchgear and controlgear -
Part 7: Ancillary equipment - Section 2:
Protective conductor terminal blocks for
copper conductors
IEC 60439-1 1999 Low-voltage switchgear and controlgear
assemblies - Part 1: Type-tested and
partially type-tested assemblies
IEC 60439-2 2000 Low-voltage switchgear and controlgear
assemblies - Part 2: Particular
requirements for busbar trunking systems
(busways)
IEC 60439-3 2001 Low-voltage switchgear and controlgear
assemblies - Part 3: Particular
requirements for low-voltage switchgear
and controlgear assemblies intended to
be installed in places where unskilled
persons have access for their use -
Distribution boards
IEC 60439-4 1999 Low-voltage switchgear and controlgear
assemblies - Part 3: Particular
requirements for low-voltage switchgear
and controlgear assemblies intended to
be installed in places where unskilled
persons have access for their use -
Distribution boards
IEC 60439-5 1999 Low-voltage switchgear and controlgear
assemblies - Part 3: Particular
requirements for low-voltage switchgear
and controlgear assemblies intended to
be installed in places where unskilled
persons have access for their use -
Distribution boards
IEC 61095 2000 Low-voltage switchgear and controlgear
assemblies - Part 3: Particular
requirements for low-voltage switchgear
and controlgear assemblies intended to
be installed in places where unskilled
persons have access for their use -
Distribution boards

ABB SACE - Electrical devices 17

 1.2 IEC standards for electrical installation

1 Standards
STANDARD YEAR TITLE
IEC 60890 1987 A method of temperature-rise assessment
by extrapolation for partially type-tested
assemblies (PTTA) of low-voltage
switchgear and controlgear
IEC 61117 1992 A method for assessing the short-circuit
withstand strength of partially type-tested
assemblies (PTTA)
IEC 60092-303 1980 Electrical installations in ships. Part 303:
Equipment - Transformers for power and
lighting
IEC 60092-301 1980 Electrical installations in ships. Part 301:
Equipment - Generators and motors
IEC 60092-101 1994 Electrical installations in ships - Part 101:
Definitions and general requirements
IEC 60092-401 1980 Electrical installations in ships. Part 401:
Installation and test of completed
installation
IEC 60092-201 1994 Electrical installations in ships - Part 201:
System design - General
IEC 60092-202 1994 Electrical installations in ships - Part 202:
System design - Protection
IEC 60092-302 1997 Electrical installations in ships - Part 302:
Low-voltage switchgear and controlgear
assemblies
IEC 60092-350 2001 Electrical installations in ships - Part 350:
Shipboard power cables - General
construction and test requirements
IEC 60092-352 1997 Electrical installations in ships - Part 352:
Choice and installation of cables for low-
voltage power systems
IEC 60364-5-52 2001 Electrical installations of buildings - Part
5-52: Selection and erection of electrical
equipment Wiring systems
IEC 60227 Polyvinyl chloride insulated cables of
rated voltages up to and including 450/
750 V
1998 Part 1: General requirements
1997 Part 2: Test methods
1997 Part 3: Non-sheathed cables for fixed
wiring
1997 Part 4: Sheathed cables for fixed wiring
1998 Part 5: Flexible cables (cords)
2001 Part 6: Lift cables and cables for flexible
connections
1995 Part 7: Flexible cables screened and
unscreened with two or more conductors
IEC 60228 1978 Conductors of insulated cables
IEC 60245 Rubber insulated cables - Rated voltages
up to and including 450/750 V
1998 Part 1: General requirements
1998 Part 2: Test methods
1994 Part 3: Heat resistant silicone insulated
cables

18 ABB SACE - Electrical devices

 1.2 IEC standards for electrical installation

1 Standards
STANDARD YEAR TITLE
1994 Part 5: Lift cables
1994 Part 6: Arc welding electrode cables
1994 Part 7: Heat resistant ethylene-vinyl
acetate rubber insulated cables
1998 Part 8: Cords for applications requiring
high flexibility
IEC 60309-2 1999 Plugs, socket-outlets and couplers for
industrial purposes - Part 2: Dimensional
interchangeability requirements for pin
and contact-tube accessories
IEC 61008-1 1996 Residual current operated circuit-breakers
without integral overcurrent protection for
household and similar uses (RCCBs) -
Part 1: General rules
IEC 61008-2-1 1990 Residual current operated circuit-breakers
without integral overcurrent protection for
household and similar uses (RCCBs).
Part 2-1: Applicability of the general rules
to RCCBs functionally independent of
line voltage
IEC 61008-2-2 1990 Residual current operated circuit-breakers
without integral overcurrent protection for
household and similar uses (RCCBs).
Part 2-2: Applicability of the general rules
to RCCBs functionally dependent on line
voltage
IEC 61009-1 1996 Residual current operated circuit-breakers
with integral overcurrent protection for
household and similar uses (RCBOs) -
Part 1: General rules
IEC 61009-2-1 1991 Residual current operated circuit-breakers
with integral overcurrent protection for
household and similar uses (RCBOs)
Part 2-1: Applicability of the general rules
to RCBOs functionally independent of
line voltage
IEC 61009-2-2 1991 Residual current operated circuit-breakers
with integral overcurrent protection for
household and similar uses (RCBOs) -
Part 2-2: Applicability of the general rules
to RCBOs functionally
dependent on line voltage
IEC 60670 1989 General requirements for enclosures for
accessories for household and similar
fixed electrical installations
IEC 60669-2-1 2000 Switches for household and similar fixed
electrical installations - Part 2-1:
Particular requirements Electronic
switches
IEC 60669-2-2 2000 Switches for household and similar fixed
electrical installations - Part 2: Particular
requirements Section 2: Remote-control
switches (RCS)
IEC 606692-3 1997 Switches for household and similar fixed
electrical installations - Part 2-3:
Particular requirements Time-delay
switches (TDS)

ABB SACE - Electrical devices 19

 1.2 IEC standards for electrical installation

1 Standards
STANDARD YEAR TITLE
IEC 60079-10 1995 Electrical apparatus for explosive gas
atmospheres - Part 10: Classification of
hazardous areas
IEC 60079-14 1996 Electrical apparatus for explosive gas
atmospheres - Part 14: Electrical
installations in hazardous areas (other
than mines)
IEC 60079-17 1996 Electrical apparatus for explosive gas
atmospheres - Part 17: Inspection and
maintenance of electrical installations in
hazardous areas (other than mines)
IEC 60269-1 1998 Low-voltage fuses - Part 1: General
requirements
IEC 60269-2 1986 Low-voltage fuses. Part 2: Supplementary
requirements for fuses for use by
authorized persons (fuses mainly for
industrial application)
IEC 60269-3-1 2000 Low-voltage fuses - Part 3-1:
Supplementary requirements for fuses for
use by unskilled persons (fuses mainly for
household and similar applications) -
Sections I to IV
IEC 60127-1/10 Miniature fuses -
1999 Part 1: Definitions for miniature fuses and
general requirements for miniature fuse-links
1989 Part 2: Cartridge fuse-links
1988 Part 3: Sub-miniature fuse-links
1996 Part 4: Universal Modular Fuse-Links
(UMF)
1988 Part 5: Guidelines for quality assessment
of miniature fuse-links
1994 Part 6: Fuse-holders for miniature
cartridge fuse-links
2001 Part 10: User guide for miniature fuses
IEC 60730-2-7 1990 Automatic electrical controls for
household and similar use. Part 2:
Particular requirements for timers and
time switches
IEC 60364-1 2001 Electrical installations of buildings - Part 1:
Fundamental principles, assessment of
general characteristics, definitions
IEC 60364-4 2001 Electrical installations of buildings - Part 4:
Protection for safety
IEC 60364-5 20012002 Electrical installations of buildings - Part 5:
Selection and erection of electrical equipment
IEC 60364-6 2001 Electrical installations of buildings - Part 6:
Verification
IEC 60364-7 19832002 Electrical installations of buildings. Part 7:
Requirements for special installations or
locations
IEC 60529 2001 Degrees of protection provided by
enclosures (IP Code)

20 ABB SACE - Electrical devices

 1.2 IEC standards for electrical installation

1 Standards
STANDARD YEAR TITLE
IEC 61032 1997 Protection of persons and equipment by
enclosures - Probes for verification
IEC 61000-1-1 1992 Electromagnetic compatibility (EMC) -
Part 1: General - Section 1: Application
and interpretation of fundamental
definitions and terms
IEC 61000-1-2 2001 Electromagnetic compatibility (EMC) -
Part 1-2: General - Methodology for the
achievement of the functional safety of
electrical and electronic equipment with
regard to electromagnetic phenomena
IEC 61000-1-3 2002 Electromagnetic compatibility (EMC) -
Part 1-3: General - The effects of high-
altitude EMP (HEMP) on civil equipment
and systems

ABB SACE - Electrical devices 21

 2 Protection of feeders

2.1 Introduction
The following definitions regarding electrical installations are derived from the
Standard IEC 60050.

Characteristics of installations
Electrical installation (of a building) An assembly of associated electrical
equipment to fulfil a specific purpose and having coordinated characteristics.

Origin of an electrical installation The point at which electrical energy is

delivered to an installation.

Neutral conductor (symbol N) A conductor connected to the neutral point of

a system and capable of contributing to the transmission of electrical energy.

Protective conductor PE A conductor required by some measures for

protection against electric shock for electrically connecting any of the following
parts:
- exposed conductive parts;
- extraneous conductive parts;
- main earthing terminal;
- earth electrode;
- earthed point of the source or artificial neutral.

PEN conductor An earthed conductor combining the functions of both

protective conductor and neutral conductor

Ambient temperature The temperature of the air or other medium where the
equipment is to be used.

Voltages
Nominal voltage (of an installation) Voltage by which an installation or part of
an installation is designated.
Note: the actual voltage may differ from the nominal voltage by a quantity within
permitted tolerances.

Currents
Design current (of a circuit) The current intended to be carried by a circuit in
normal service.

Current-carrying capacity (of a conductor) The maximum current which can

be carried continuously by a conductor under specified conditions without its
steady-state temperature exceeding a specified value.

Overcurrent Any current exceeding the rated value. For conductors, the rated
value is the current-carrying capacity.

Overload current (of a circuit) An overcurrent occurring in a circuit in the

absence of an electrical fault.

Short-circuit current An overcurrent resulting from a fault of negligible

impedance between live conductors having a difference in potential under normal

22 ABB SACE - Electrical devices

 2.1 Introduction

2 Protection of feeders
operating conditions.

Conventional operating current (of a protective device) A specified value of

the current which cause the protective device to operate within a specified
time, designated conventional time.

Overcurrent detection A function establishing that the value of current in a

circuit exceeds a predetermined value for a specified length of time.

Leakage current Electrical current in an unwanted conductive path other than

a short circuit.

Fault current The current flowing at a given point of a network resulting from
a fault at another point of this network.

Wiring systems
Wiring system An assembly made up of a cable or cables or busbars and the
parts which secure and, if necessary, enclose the cable(s) or busbars.

Electrical circuits
Electrical circuit (of an installation) An assembly of electrical equipment of
the installation supplied from the same origin and protected against overcurrents
by the same protective device(s).

Distribution circuit (of buildings) A circuit supplying a distribution board.

Final circuit (of building) A circuit connected directly to current using

equipment or to socket-outlets.

Other equipment
Electrical equipment Any item used for such purposes as generation,
conversion, transmission, distribution or utilization of electrical energy, such as
machines, transformers, apparatus, measuring instruments, protective devices,
equipment for wiring systems, appliances.

Current-using equipment Equipment intended to convert electrical energy

into another form of energy, for example light, heat, and motive power

Switchgear and controlgear Equipment provided to be connected to an

electrical circuit for the purpose of carrying out one or more of the following
functions: protection, control, isolation, switching.

Portable equipment Equipment which is moved while in operation or which

can easily be moved from one place to another while connected to the supply.

Hand-held equipment Portable equipment intended to be held in the hand

during normal use, in which the motor, if any, forms an integral part of the
equipment.

Stationary equipment Either fixed equipment or equipment not provided with

a carrying handle and having such a mass that it cannot easily be moved.

Fixed equipment Equipment fastened to a support or otherwise secured in a

specific location.

ABB SACE - Electrical devices 23

 2.1 Introduction

2 Protection of feeders
Installation dimensioning
The flow chart below suggests the procedure to follow for the correct
dimensioning of a plant.

Load analysis:
- definition of the power absorbed by the loads and relevant position;
- definition of the position of the power distribution centers (switchboards);
- definition of the paths and calculation of the length of the connection elements;
- definition of the total power absorbed, taking into account the utilization factors
and demand factors.

Dimensioning of transformers and generators with margin connected to

future predictable power supply requirements (by approximation from +1530%)

Dimensioning of conductors:
- evaluation of the current (I b ) in the single connection elements;
- definition of the conductor type (conductors and insulation materials,
configuration,...);
- definition of the cross section and of the current carrying capacity;
- calculation of the voltage drop at the load current under specific reference
conditions (motor starting,).

Verification of the voltage drop limits at the final loads

negative
outcome

Short-circuit current calculation maximum values at the busbars (beginning of

line) and minimum values at the end of line

Selection of protective circuit-breakers with:

- breaking capacity higher than the maximum prospective short-circuit current;
- rated current In not lower than the load curren Ib;
- characteristics compatible with the type of protected load (motors, capacitors...).

Verification of the protection of conductors:

- verification of the protection against overload: the rated current or the set current
of the circuit-breaker shall be higher than the load current, but lower than the
current carrying capacity of the conductor:
Ib In Iz
- verification of the protection against short-circuit: the specific let-through energy negative
outcome
by the circuit breaker under short-circuit conditions shall be lower than the specific
let-through energy which can be withstood by the cable:
I2t k2S2
- verification of the protection against indirect contacts (depending on the
distribution system).
1SDC010001F0901

Verification of the coordination with other equipments (discrimination and

negative back-up, verification of the coordination with switch disconnectors...)
outcome

Definition of the components (auxiliary circuits, terminals) and switchboard

design

24 ABB SACE - Electrical devices

 2 Protection of feeders

2.2 Installation and dimensioning of cables

For a correct dimensioning of a cable, it is necessary to:

choose the type of cable and installation according to the environment;
choose the cross section according to the load current;
verify the voltage drop.

2.2.1 Current carrying capacity and methods of installation

Selection of the cable
The international reference Standard ruling the installation and calculation of
the current carrying capacity of cables in residential and industrial buildings is
IEC 60364-5-52 Electrical installations of buildings Part 5-52 Selection and
Erection of Electrical Equipment- Wiring systems.
The following parameters are used to select the cable type:
conductive material (copper or aluminium): the choice depends on cost,
dimension and weight requirements, resistance to corrosive environments
(chemical reagents or oxidizing elements). In general, the carrying capacity of
a copper conductor is about 30% greater than the carrying capacity of an
aluminium conductor of the same cross section. An aluminium conductor of
the same cross section has an electrical resistance about 60% higher and a
weight half to one third lower than a copper conductor.

insulation material (none, PVC, XLPE-EPR): the insulation material affects the
maximum temperature under normal and short-circuit conditions and therefore
the exploitation of the conductor cross section [see Chapter 2.4 Protection
against short-circuit].

the type of conductor (bare conductor, single-core cable without sheath, single-
core cable with sheath, multi-core cable) is selected according to mechanical
resistance, degree of insulation and difficulty of installation (bends, joints along
the route, barriers...) required by the method of installation.

Table 1 shows the types of conductors permitted by the different methods of

installation.
Table 1: Selection of wiring systems
Method of installation
Cable trunking
(including skirting Cable ladder
Conductors and Without Clipped trunking, flush floor Cable Cable tray On in- Support
cables fixings direct Conduit trunking) ducting Cable brackets sulators wire
Bare conductors - - - - - - + -
Insulated conductors - - + + + - + -
Sheathed cables
Multi-core + + + + + + 0 +
(including armoured and
mineral insulated)
Single-core 0 + + + + + 0 +

+ Permitted.
Not permitted.
0 Not applicable, or not normally used in practice.

ABB SACE - Electrical devices 25

 2.2 Installation and dimensioning of cables

2 Protection of feeders
For industrial installations, multi-core cables are rarely used with cross section
greater than 95 mm2.

Methods of installation
To define the current carrying capacity of the conductor and therefore to identify
the correct cross section for the load current, the standardized method of
installation that better suits the actual installation situation must be identified
among those described in the mentioned reference Standard.
From Tables 2 and 3 it is possible to identify the installation identification number,
the method of installation (A1, A2, B1, B2, C, D, E, F, G) and the tables to
define the theoretical current carrying capacity of the conductor and any
correction factors required to allow for particular environmental and installation
situations.

Table 2: Method of installation

Method of installation
Cable trunking
(including skirting Cable ladder
Without With trunking, flush floor Cable Cable tray On Support
Situations fixings fixings Conduit trunking) ducting Cable brackets insulators wire
40, 46, 30, 31,
Building voids 0 15, 16 - 0 - -
15, 16 32, 33, 34
30, 31, 32,
Cable channel 56 56 54, 55 0 44 - -
33, 34
Buried in
72, 73 0 70, 71 - 70, 71 0 - -
Ground
Embedded in 1, 2 50, 51, 52,
57, 58 3 44, 45 0 - -
Structure 59, 60 53
Surface 6, 7, 8, 9, 30, 31,
- 20, 21 4, 5 6, 7, 8, 9 36 -
Mounted 12, 13, 14 32, 33, 34
30, 31, 32,
Overhead - - 0 10, 11 - 36 35
33, 34

The number in each box indicates the item number in Table 3.

- Not permitted.
0 Not applicable or not normally used in practice.

26 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Table 3: Examples of methods of installation
Reference
method of
installation to be
Methods of
Item n. Description used to
installation
obtain current-
carrying
capacity

Insulated conductors or single-core

Room 1 cables in conduit in a thermally A1
insulated wall

Multi-core cables in conduit in a

Room 2
thermally insulated wall
A2

Multi-core cable direct in a thermally

Room 3
insulated wall
A1

Insulated conductors or single-core

cables in conduit on a wooden, or
4
masonry wall or spaced less than 0.3 B1
times conduit diameter from it
Multi-core cable in conduit on a
wooden, or masonry wall or spaced
5
less than 0.3 times conduit diameter B2
from it
Insulated conductors or single-core
cables in cable trunking on a wooden
6
7
wall run horizontally (6) B1
run vertically (7)
Insulated conductors or single-core
cable in suspended cable trunking
8 (8) B1 (8) or B2 (9)
9 Multi-core cable in suspended cable
trunking (9)

Insulated conductors or single-core

12
cable run in mouldings A1

TV TV
Insulated conductors or single-core B1 (13)
13 cables in skirting trunking (13)
ISDN ISDN
Multi-core cable in skirting trunking or
14
(14) B2 (14)
Insulated conductors in conduit or
15 single-core or multi-core cable in A1
architrave
Insulated conductors in conduit or
16 single-core or multi-core cable in A1
window frames
1SDC010001F0201

Single-core or multi-core cables:

fixed on, or spaced less than 0.3
20 times (20)
cable diameter from a wooden wall C
21
fixed directly under a wooden
ceiling (21)

ABB SACE - Electrical devices 27

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Reference
method of
installation to be
Methods of Methods of
Item n. Description used to
installation installation
obtain current-
carrying
capacity
0.3 De

De
1
30 On unperforated tray C

0.3 De

De
0.3 De

1
31 On perforated tray E or F

0.3 De

0.3 De

De
1
32 On brackets or on a wire mesh E or F

0.3 De

Spaced more than 0.3 times cable

33
diameter from a wall E or F or G

34 On ladder E or F TV

ISDN IS

Single-core or multi-core cable

35 suspended from or incorporating a E or F
support wire

Bare or insulated conductors on De

36
insulators G

28 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Reference Reference
method of method of
installation to be installation to be
Methods of
used to Item n. Description used to
installation
obtain current- obtain current-
carrying carrying
capacity capacity

1.5 De V < 20 De
Single-core or multi-core cable in a B2
De V 40 2
building void V 20 De
C B1

1.5 De V < 20 De
Insulated conductors in cable ducting B2
V 24 2
De in a building void V 20 De
B1

1.5 De V < 5 De
E or F
Insulated conductors in cable ducting B2
V 44 in masonry having a thermal
resistivity not greater than 2 Km/W 5 De V < 50 De
B1

1.5 De V < 5 D e
V Single-core or multi-core cable:
De 46 in a ceiling void B2
1
E or F in a suspended floor
5 De V < 50De
B1
Insulated conductors or single-core
50 cable in flush cable trunking in the B1
floor
E or F or G Multi-core cable in flush cable
51
trunking in the floor
B2

E or F TV TV Insulated conductors or single-core B1 (52)

52 cables in embedded trunking (52)
ISDN ISDN Multi-core cable in embedded
or
53 B2 (53)
trunking (53)

E or F

1.5 De V < 20 De
1SDC010002F0201

Insulated conductors or single-core

V 54
cables in conduit in an unventilated B2
De cable channel run horizontally or
G vertically
2 V 20 De
B1

ABB SACE - Electrical devices 29

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Reference
method of
installation to be
Methods of
Item n. Description used to
installation
obtain current-
carrying
capacity

Insulated conductors in conduit in an

55 open or ventilated cable channel in B1
the floor

Sheathed single-core or multi-core

56 cable in an open or ventilated cable B1
channel run horizontally or vertically

Single-core or multi-core cable direct

in masonry having a thermal
57
resistivity not greater than 2 Km/W
C
Without added mechanical protection

Single-core or multi-core cable direct

in masonry having a thermal
58
resistivity not greater than 2 Km/W
C
With added mechanical protection

Insulated conductors or single-core

59
cables in conduit in masonry B1

Multi-core cables in conduit in

60
masonry B2

Multi-core cable in conduit or in cable

70
ducting in the ground D

Single-core cable in conduit or in

71
cable ducting in the ground D

Sheathed single-core or multi-core

cables direct in the ground
1SDC010003F0201

72 without added mechanical D

protection

Sheathed single-core or multi-core

73 cables direct in the ground D
with added mechanical protection
1
De is the external diameter of a multi-core cable:
2.2 x the cable diameter when three single core cables are bound in trefoil, or
3 x the cable diameter when three single core cables are laid in flat formation.
2
De is the external diameter of conduit or vertical depth of cable ducting.
V is the smaller dimension or diameter of a masonry duct or void, or the vertical depth of a rectangular duct, floor or ceiling void.
The depth of the channel is more important than the width.

30 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Installation not buried in the ground: choice of the
cross section according to cable carrying capacity and
type of installation
The cable carrying capacity of a cable that is not buried in the ground is obtained
by using this formula:
I z = I 0 k1k2 = I 0 ktot
where:
I0 is the current carrying capacity of the single conductor at 30 C reference
ambient temperature;
k1 is the correction factor if the ambient temperature is other than 30 C;
k2 is the correction factor for cables installed bunched or in layers or for
cables installed in a layer on several supports.

Correction factor k1
The current carrying capacity of the cables that are not buried in the ground
refers to 30 C ambient temperature. If the ambient temperature of the place
of installation is different from this reference temperature, the correction factor
k1 on Table 4 shall be used, according to the insulation material.

Table 4: Correction factor for ambient air temperature other than 30 C

Insulation
Mineral (a)
Ambient PVC covered or
temperature (a) bare and exposed Bare not exposed
C PVC XLPE and EPR to touch 70 C to touch 105 C
10 1.22 1.15 1.26 1.14
15 1.17 1.12 1.20 1.11
20 1.12 1.08 1.14 1.07
25 1.06 1.04 1.07 1.04
35 0.94 0.96 0.93 0.96
40 0.87 0.91 0.85 0.92
45 0.79 0.87 0.87 0.88
50 0.71 0.82 0.67 0.84
55 0.61 0.76 0.57 0.80
60 0.50 0.71 0.45 0.75
65 0.65 0.70
70 0.58 0.65
75 0.50 0.60
80 0.41 0.54
85 0.47
90 0.40
95 0.32
(a)
For higher ambient temperatures, consult manufacturer.

ABB SACE - Electrical devices 31

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Correction factor k2
The cable current carrying capacity is influenced by the presence of other cables
installed nearby. The heat dissipation of a single cable is different from that of
the same cable when installed next to the other ones. The factor k2 is tabled
according to the installation of cables laid close together in layers or bunches.

Definition of layer or bunch

layer: several circuits constituted by cables installed one next to another, spaced
or not, arranged horizontally or vertically. The cables on a layer are installed on
a wall, tray, ceiling, floor or on a cable ladder;

> 2 De2

a)

De1 De2

b)
< 30 cm

c)
1SDC010002F0001

Cables in layers: a) spaced; b) not spaced; c) double layer

bunch: several circuits constituted by cables that are not spaced and are not
installed in a layer; several layers superimposed on a single support (e.g. tray)
are considered to be a bunch.

32 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders

a)

b)

1SDC010003F0001
c)

Bunched cables: a) in trunking; b) in conduit; c) on perforated tray

The value of correction factor k2 is 1 when:

the cables are spaced:
- two single-core cables belonging to different circuits are spaced when the
distance between them is more than twice the external diameter of the
cable with the larger cross section;
- two multi-core cables are spaced when the distance between them is at
least the same as the external diameter of the larger cable;
the adjacent cables are loaded less than 30 % of their current carrying capacity.

The correction factors for bunched cables or cables in layers are calculated by
assuming that the bunches consist of similar cables that are equally loaded. A
group of cables is considered to consist of similar cables when the calculation
of the current carrying capacity is based on the same maximum allowed
operating temperature and when the cross sections of the conductors is in the
range of three adjacent standard cross sections (e.g. from 10 to 25 mm2).
The calculation of the reduction factors for bunched cables with different cross
sections depends on the number of cables and on their cross sections. These
factors have not been tabled, but must be calculated for each bunch or layer.

ABB SACE - Electrical devices 33

 2.2 Installation and dimensioning of cables

2 Protection of feeders
The reduction factor for a group containing different cross sections of insulated
conductors or cables in conduits, cable trunking or cable ducting is:

1
k2 =
n
where:
k2 is the group reduction factor;
n is the number of circuits of the bunch.
The reduction factor obtained by this equation reduces the danger of overloading
of cables with a smaller cross section, but may lead to under utilization of
cables with a larger cross section. Such under utilization can be avoided if large
and small cables are not mixed in the same group.

The following tables show the reduction factor (k2).

Table 5: Reduction factor for grouped cables

To be used with
current-carrying
Arrangement Number of circuits or multi-core cables capacities,
Item (cables touching) 1 2 3 4 5 6 7 8 9 12 16 20 reference
1 Bunched in air, on a 1.00 0.80 0.70 0.65 0.60 0.57 0.54 0.52 0.50 0.45 0.41 0.38
surface, embedded or Methods A to F
enclosed
2 Single layer on wall, 1.00 0.85 0.79 0.75 0.73 0.72 0.72 0.71 0.70
floor or unperforated
tray
0.95 0.81 0.72 0.68 0.66 0.64 0.63 0.62 0.61 No further
3 Single layer fixed
reduction
directly under a factor for more Method C
wooden ceiling than
nine circuits or
4 Single layer on a 1.00 0.88 0.82 0.77 0.75 0.73 0.73 0.72 0.72
multicore cables
perforated horizontal or
vertical tray
5 Single layer on ladder 1.00 0.87 0.82 0.80 0.80 0.79 0.79 0.78 0.78 Methods E and F
support or cleats etc.

NOTE 1 These factors are applicable to uniform groups of cables, equally loaded.
NOTE 2 Where horizontal clearances between adjacent cables exceeds twice their overall diameter, no reduction
factor need be applied.
NOTE 3 The same factors are applied to:
groups of two or three single-core cables;
multi-core cables.
NOTE 4 If a system consists of both two- and three-core cables, the total number of cables is taken as the number of
circuits, and the corresponding factor is applied to the tables for two loaded conductors for the two-core
cables, and to the tables for three loaded conductors for the three-core cables.
NOTE 5 If a group consists of n single-core cables it may either be considered as n/2 circuits of two loaded
conductors or n/3 circuits of three loaded conductors.

34 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Table 6: Reduction factor for single-core cables with method of
installation F

Number of three-phase Use as a

Number of circuits (note 4)
Method of installation in Table 3 multiplier to
trays
1 2 3 rating for

Touching
Perforated 1 0.98 0.91 0.87
Three cables in
trays 31 2 0.96 0.87 0.81 horizontal
(note 2) formation
3 0.95 0.85 0.78
20 mm
Touching

Vertical
perforated 1 0.96 0.86 Three cables in
trays 31 vertical
225 mm 2 0.95 0.84 formation
(note 3)

Touching
Ladder
32 1 1.00 0.97 0.96
supports, Three cables in
33 2 0.98 0.93 0.89 horizontal
cleats, etc.
formation
34 3 0.97 0.90 0.86
(note 2)
20 mm

Perforated 2D
2 D ee 1 1.00 0.98 0.96
trays D
Dee
31 2 0.97 0.93 0.89
(note 2) 3 0.96 0.92 0.86
20 mm
Spaced
Vertical
perforated 2 D e 1 1.00 0.91 0.89 Three cables in
trays 31 trefoil formation
225 mm 2 1.00 0.90 0.86
(note 3)
De

Ladder 32 1 1.00 1.00 1.00

2 D e De
supports,
cleats, etc. 33 2 0.97 0.95 0.93

(note 2) 34 3 0.96 0.94 0.90

20 mm

NOTE 1 Factors are given for single layers of cables (or trefoil groups) as shown in the table and do not apply
when cables are installed in more than one layer touching each other. Values for such installations may be
significantly lower and must be determined by an appropriate method.
NOTE 2 Values are given for vertical spacings between trays of 300 mm. For closer spacing the factors should be
reduced.
1SDC010004F0201

NOTE 3 Values are given for horizontal spacing between trays of 225 mm with trays mounted back to back and at
least 20 mm between the tray and any wall. For closer spacing the factors should be reduced.
NOTE 4 For circuits having more than one cable in parallel per phase, each three phase set of conductors should
be considered as a circuit for the purpose of this table.

ABB SACE - Electrical devices 35

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Table 7: Reduction factor for multi-core cables with method of
installation E

Number Number of cables

Method of installation in Table 3
of trays 1 2 3 4 6 9
Touching
1 1.00 0.88 0.82 0.79 0.76 0.73
2 1.00 0.87 0.80 0.77 0.73 0.68
3 1.00 0.86 0.79 0.76 0.71 0.66
Perforated 20 mm
trays 31
Spaced
(note 2) 1 1.00 1.00 0.98 0.95 0.91
De
2 1.00 0.99 0.96 0.92 0.87
3 1.00 0.98 0.95 0.91 0.85
20 mm
Touching

1 1.00 0.88 0.82 0.78 0.73 0.72

225 mm 2 1.00 0.88 0.81 0.76 0.71 0.70

Vertical
perforated
trays 31
Spaced
(note 3)

1 1.00 0.91 0.89 0.88 0.87

2 1.00 0.91 0.88 0.87 0.85
D
Dee
225 mm

Touching
1 1.00 0.87 0.82 0.80 0.79 0.78
2 1.00 0,86 0.80 0.78 0.76 0.73
3 1.00 0.85 0.79 0.76 0.73 0.70
Ladder 32 20 mm
supports,
33 Spaced
cleats, etc.
34 DDee
(note 2) 1 1.00 1.00 1.00 1.00 1.00
2 1.00 0.99 0.98 0.97 0.96
3 1.00 0.98 0.97 0.96 0.93
20 mm

NOTE 1 Factors apply to single layer groups of cables as shown above and do not apply when cables are installed in
more than one layer touching each other. Values for such installations may be significantly lower and must be
determined by an appropriate method.
NOTE 2 Values are given for vertical spacings between trays of 300 mm and at least 20 mm between trays and wall.
1SDC010005F0201

For closer spacing the factors should be reduced.

NOTE 3 Values are given for horizontal spacing between trays of 225 mm with trays mounted back to back. For closer
spacing the factors should be reduced.

36 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders
To summarize:
The following procedure shall be used to determine the cross section
of the cable:
1. from Table 3 identify the method of installation;

2. from Table 4 determine the correction factor k1 according to

insulation material and ambient temperature;

3. use Table 5 for cables installed in layer or bunch, Table 6 for single-
core cables in a layer on several supports, Table 7 for multi-core
cables in a layer on several supports or the formula shown in the
case of groups of cables with different sections to determine the
correction factor k2 appropriate for the numbers of circuits or multi-
core cables;

4. calculate the value of current Ib by dividing the load current Ib (or

the rated current of the protective device) by the product of the
correction factors calculated:

Ib I
I'b = = b
k1k2 k tot

5. from Table 8 or from Table 9, depending on the method of installation, on

insulation and conductive material and on the number of live conductors,
determine the cross section of the cable with capacity I0 Ib;

6. the actual cable current carrying capacity is calculated by IZ = I0 k1 k2.

ABB SACE - Electrical devices 37

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Table 8: Current carrying capacity of cables with PVC or EPR/XLPE
insulation (method A-B-C)
Installation
A1 A2 B1
method

Conductor Cu Al Cu Al Cu Al
XLPE XLPE XLPE XLPE XLPE XLPE
Insulation EPR PVC EPR PVC EPR PVC EPR PVC EPR PVC EPR P

Loaded 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2
conductors
S[mm2]
1.5 19 17 14.5 13.5 13
18.5 16.5 14 13.0 23 20 17.5 15.5
2.5 26 23 19.5 18 20 19 14.5 14 25 22 18.5 17.5 19.5 18 14.5 13.5 31 28 24 21 25 22 18.5
4 35 31 26 24 27 25 20 18.5 33 30 25 23 26 24 20 17.5 42 37 32 28 33 29 25
6 45 40 34 31 35 32 26 24 42 38 32 29 33 31 25 23 54 48 41 36 43 38 32
10 61 54 46 42 48 44 36 32 57 51 43 39 45 41 33 31 75 66 57 50 59 52 44
16 81 73 61 56 64 58 48 43 76 68 57 52 60 55 44 41 100 88 76 68 79 71 60
25 106 95 80 73 84 76 63 57 99 89 75 68 78 71 58 53 133 117 101 89 105 93 79
35 131 117 99 89 103 94 77 70 121 109 92 83 96 87 71 65 164 144 125 110 130 116 97
50 158 141 119 108 125 113 93 84 145 130 110 99 115 104 86 78 198 175 151 134 157 140 118
70 200 179 151 136 158 142 118 107 183 164 139 125 145 131 108 98 253 222 192 171 200 179 150
95 241 216 182 164 191 171 142 129 220 197 167 150 175 157 130 118 306 269 232 207 242 217 181
120 278 249 210 188 220 197 164 149 253 227 192 172 201 180 150 135 354 312 269 239 281 251 210
150 318 285 240 216 253 226 189 170 290 259 219 196 230 206 172 155
185 362 324 273 245 288 256 215 194 329 295 248 223 262 233 195 176
240 424 380 321 286 338 300 252 227 386 346 291 261 307 273 229 207
300 486 435 367 328 387 344 289 261 442 396 334 298 352 313 263 237
400
500
630

38 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders

B1 B2 C

Al Cu Al Cu Al Cu Al
E XLPE XLPE XLPE XLPE XLPE
R PVC EPR PVC EPR PVC EPR PVC EPR PVC EPR PVC XLPE/EPR PVC

3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3

23 20 17.5 15.5 22 19.5 16.5 15 24 22 19.5 17.5

18 14.5 13.5 31 28 24 21 25 22 18.5 16.5 30 26 23 20 23 21 17.5 15.5 33 30 27 24 26 24 21 18.5
24 20 17.5 42 37 32 28 33 29 25 22.0 40 35 30 27 31 28 24 21 45 40 36 32 35 32 28 25
25.0
31 25 23 54 48 41 36 43 38 32 28 51 44 38 34 40 35 30 27.0 58 52 46 41 45 41 36 32
41 33 31 75 66 57 50 59 52 44 39 69 60 52 46 54 48 41 36 80 71 63 57 62 57 49 44
55 44 41 100 88 76 68 79 71 60 53 91 80 69 62 72 64 54 48 107 96 85 76 84 76 66 59
71 58 53 133 117 101 89 105 93 79 70 119 105 90 80 94 84 71 62 138 119 112 96 101 90 83 73
87 71 65 164 144 125 110 130 116 97 86 146 128 111 99 115 103 86 77 171 147 138 119 126 112 103 90
104 86 78 198 175 151 134 157 140 118 104 175 154 133 118 138 124 104 92 209 179 168 144 154 136 125 110
131 108 98 253 222 192 171 200 179 150 133 221 194 168 149 175 156 131 116 269 229 213 184 198 174 160 140
157 130 118 306 269 232 207 242 217 181 161 265 233 201 179 210 188 157 139 328 278 258 223 241 211 195 170
180 150 135 354 312 269 239 281 251 210 186 305 268 232 206 242 216 181 160 382 322 299 259 280 245 226 197
206 172 155 441 371 344 299 324 283 261 227

1SDC010006F0201
233 195 176 506 424 392 341 371 323 298 259
273 229 207 599 500 461 403 439 382 352 305
313 263 237 693 576 530 464 508 440 406 351

ABB SACE - Electrical devices 39

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Table 8: Current carrying capacity of cables with PVC or EPR/XLPE
insulation (method E-F-G)
Installation
method F
E

or or

Cu Al Cu Al Cu Al Cu Al Cu Al
XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE
Insulation EPR PVC EPR PVC EPR PVC EPR PVC EPR PVC EPR PVC EPR PVC EPR PVC EPR PVC EPR PVC

Loaded 2 3 2 3 3
conductors
S[mm2]
1.5 26 22 23 18.5
2.5 36 30 28 23 32 2 24 19.5 5
4 49 40 38 31 42 34 32 26
6 63 51 49 39 54 43 42 33
10 86 70 67 54 75 60 58 46
16 115 94 91 73 100 80 77 61
25 149 119 108 89 127 101 97 78 161 131 121 98 13 110 103 845 141 114 107 87
35 185 148 135 111 158 126 120 96 200 162 150 122 169 137 129 105 176 143 135 109
50 225 180 164 135 192 153 146 117 242 196 184 149 207 167 159 128 216 174 165 133
70 289 232 211 173 246 196 187 150 310 251 237 192 268 216 206 166 279 225 215 173
95 352 282 257 210 298 238 227 183 377 304 289 235 328 264 253 203 342 275 264 212
120 410 328 300 244 346 276 263 212 437 352 337 273 383 308 296 237 400 321 308 247
150 473 379 346 282 399 319 304 245 504 406 389 316 444 356 343 274 464 372 358 287
185 542 434 397 322 456 364 347 280 575 463 447 363 510 409 395 315 533 427 413 330
240 641 514 470 380 538 430 409 330 679 546 530 430 607 485 471 375 634 507 492 392
300 741 593 543 439 621 497 471 381 783 629 613 497 703 561 547 434 736 587 571 455
400 940 754 740 600 823 656 663 526 868 689 694 552
500 1083 868 856 694 946 749 770 610 998 789 806 640
630 1254 1005 996 808 1088 855 899 711 1151 905 942 746

40 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders

F G

or De
De
Cu Al Cu Al Cu Al
XLPE XLPE XLPE XLPE XLPE XLPE
C EPR PVC EPR PVC EPR PVC EPR PVC EPR PV C EPR PV

3 3 3H 3V 3H 3V 3H 3V 3H 3V

8 13 110 103 845 141 114 107 87 182 161 146 130 138 122 112 99
2 169 137 129 105 176 143 135 109 226 201 181 162 172 153 139 124
9 207 167 159 128 216 174 165 133 275 246 219 197 210 188 169 152
2 268 216 206 166 279 225 215 173 353 318 281 254 271 244 217 196
5 328 264 253 203 342 275 264 212 430 389 341 311 332 300 265 241
3 383 308 296 237 400 321 308 247 500 454 396 362 387 351 308 282
6 444 356 343 274 464 372 358 287 577 527 456 419 448 408 356 327
1SDC010100F0201

3 510 409 395 315 533 427 413 330 661 605 521 480 515 470 407 376
0 607 485 471 375 634 507 492 392 781 719 615 569 611 561 482 447
7 703 561 547 434 736 587 571 455 902 833 709 659 708 652 557 519
0 823 656 663 526 868 689 694 552 1085 1008 852 795 856 792 671 629
4 946 749 770 610 998 789 806 640 1253 1169 982 920 991 921 775 730
8 1088 855 899 711 1151 905 942 746 1454 1362 1138 1070 1154 1077 900 852

ABB SACE - Electrical devices 41

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Table 9: Current carrying capacity of cables with mineral insulation

Installation C E or F
method
Metallic sheath temperature 70 C Metallic sheath temperature 105 C Metallic sheath temperature 70 C Metallic sheath t
Sheath PVC covered or Bare cable not PVC covered or Bare c
bare exposed to touch exposed to touch bare exposed to touch exposed
e

Loaded or or or or
conductors

S[mm2] 2 3 3 2 3 3 2 3 3 2
1.5 23 19 21 28 24 27 25 21 23 31
500 V 2.5 31 26 29 38 33 36 33 28 31 41
4 40 35 38 51 44 47 44 37 41 54
1.5 25 21 23 31 26 30 26 22 26 33
2.5 34 28 31 42 35 41 36 30 34 45
4 45 37 41 55 47 53 47 40 45 60
6 57 48 52 70 59 67 60 51 57 76
10 77 65 70 96 81 91 82 69 77 104
16 102 86 92 127 107 119 109 92 102 137
25 133 112 120 166 140 154 142 120 132 179
750 V 35 163 137 147 203 171 187 174 147 161 220
50 202 169 181 251 212 230 215 182 198 272
70 247 207 221 307 260 280 264 223 241 333
95 296 249 264 369 312 334 317 267 289 400
120 340 286 303 424 359 383 364 308 331 460
150 388 327 346 485 410 435 416 352 377 526
185 440 371 392 550 465 492 472 399 426 596
240 514 434 457 643 544 572 552 466 496 697

Note 1 For single-core cables the sheaths of the cables of the circuit are connected together at both ends.
Note 2 For bare cables exposed to touch, values should be multiplied by 0.9.
Note 3 De is the external diameter of the cable.
Note 4 For metallic sheath temperature 105 C no correction for grouping need to be applied.

42 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders

E or F G

C Metallic sheath temperature 70 C Metallic sheath temperature 105 C Metallic sheath temperature 70 C Metallic sheath temperature 105 C
PVC covered or Bare cable not PVC covered or Bare cable not
bare exposed to touch exposed
e to touch bare exposed to touch exposed to touch

or or or or or or
De De
De De

2 3 3 2 3 3 3 3 3 3
25 21 23 31 26 29 26 29 33.0
33 37.0
37
33 28 31 41 35 39 34 39 43 49
44 37 41 54 46 51 45 51 56 64
26 22 26 33 28 32 28 32 35 40
36 30 34 45 38 43 37 43 47 54
47 40 45 60 50 56 49 56 61 70
60 51 57 76 64 71 62 71 78 89
82 69 77 104 87 96 84 95 105 120
109 92 102 137 115 127 110 125 137 157
142 120 132 179 150 164 142 162 178 204
174 147 161 220 184 200 173 197 216 248
215 182 198 272 228 247 213 242 266 304

1SDC010007F0201
264 223 241 333 279 300 259 294 323 370
317 267 289 400 335 359 309 351 385 441
364 308 331 460 385 411 353 402 441 505
416 352 377 526 441 469 400 454 498 565
472 399 426 596 500 530 446 507 557 629
552 466 496 697 584 617 497 565 624 704

at both ends.

ABB SACE - Electrical devices 43

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Installation in ground: choice of the cross section according
to cable carrying capacity and type of installation
The current carrying capacity of a cable buried in the ground is calculated by
using this formula:

I z = I 0 k1k 2k 3 = I 0 k tot

where:
I0 is the current carrying capacity of the single conductor for installation in the
ground at 20C reference temperature;
k1 is the correction factor if the temperature of the ground is other than 20C;
k2 is the correction factor for adjacent cables;
k3 is the correction factor if the soil thermal resistivity is different from the
reference value, 2.5 Km/W.

Correction factor k1
The current carrying capacity of buried cables refers to a ground temperature
of 20 C. If the ground temperature is different, use the correction factor k1
shown in Table 10 according to the insulation material.

Table 10: Correction factors for ambient ground temperatures other

than 20 C
Insulation
Ground
temperature
C PVC XLPE and EPR
10 1.10 1.07
15 1.05 1.04
25 0.95 0.96
30 0.89 0.93
35 0.84 0.89
40 0.77 0.85
45 0.71 0.80
50 0.63 0.76
55 0.55 0.71
60 0.45 0.65
65 0.60
70 0.53
75 0.46
80 0.38

44 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Correction factor k2
The cable current carrying capacity is influenced by the presence of other cables
installed nearby. The heat dissipation of a single cable is different from that of
the same cable installed next to the other ones.
The correction factor k2 is obtained by the formula:

k2 = k 2' . k 2''

Tables 11, 12, and 13 show the factor k2 values for single-core and multi-core
cables that are laid directly in the ground or which are installed in buried ducts,
according to their distance from other cables or the distance between the ducts.

Table 11: Reduction factors for cables laid directly in the ground

Cable to cable clearance (a)

Number Nil (cables One cable
of circuits touching) diameter 0.125 m 0.25 m 0.5 m
2 0.75 0.80 0.85 0.90 0.90
3 0.65 0.70 0.75 0.80 0.85
4 0.60 0.60 0.70 0.75 0.80
5 0.55 0.55 0.65 0.70 0.80
6 0.50 0.55 0.60 0.70 0.80

Multi-core cables

a a

Single-core cables

a a
NOTE The given values apply to an installation depth of 0.7 m and a soil thermal resistivity of 2.5 Km/W.

ABB SACE - Electrical devices 45

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Table 12: Reduction factors for multi-core cables laid in single way
ducts in the ground
Cable to cable clearance (a)
Number Nil (cables
of circuits touching) 0.25 m 0.5 m 1.0 m
2 0.85 0.90 0.95 0.95
3 0.75 0.85 0.90 0.95
4 0.70 0.80 0.85 0.90
5 0.65 0.80 0.85 0.90
6 0.60 0.80 0.80 0.90

Multi-core cables

NOTE The given values apply to an installation depth of 0.7 m and a soil thermal resistivity of 2.5 Km/W.

Table 13: Reduction factors for single-core cables laid in single way
ducts in the ground
Duct to duct clearance (a)
Number of single-core
circuits of Nil (ducts
two or three cables touching) 0.25 m 0.5 m 1.0 m
2 0.80 0.90 0.90 0.95
3 0.70 0.80 0.85 0.90
4 0.65 0.75 0.80 0.90
5 0.60 0.70 0.80 0.90
6 0.60 0.70 0.80 0.90
Single-core cables

a a

NOTE The given values apply to an installation depth of 0.7 m and a soil thermal resistivity of 2.5 Km/W.

46 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders
For correction factor k2:
for cables laid directly in the ground or if there are not other conductors within
the same duct, the value of k2 is 1;
if several conductors of similar sizes are present in the same duct (for the
meaning of group of similar conductors, see the paragraphs above), k2 is
obtained from the first row of Table 5;
if the conductors are not of similar size, the correction factor is calculated by
using this formula:

1
k 2'' =
n

where:
n is the number of circuits in the duct.

Correction factor k3
Soil thermal resistivity influences the heat dissipation of the cable. Soil with low
thermal resistivity facilitates heat dissipation, whereas soil with high thermal
resistivity limits heat dissipation. IEC 60364-5-52 states as reference value for
the soil thermal resistivity 2.5 Km/W.

Table 14: Correction factors for soil thermal resistivities other than
2.5 Km/W
Thermal resistivities Km/W 1 1.5 2 2.5 3
Correction factor 1.18 1.1 1.05 1 0.96

Note 1: the overall accuracy of correction factors is within 5%.

Note 2: the correction factors are applicable to cables drawn into buried ducts; for cables
laid direct in the ground the correction factors for thermal resistivities less than 2.5 Km/W
will be higher. Where more precise values are required they may be calculated by methods
given in IEC 60287.
Note 3: the correction factors are applicable to ducts buried at depths of up to 0.8 m.

ABB SACE - Electrical devices 47

 2.2 Installation and dimensioning of cables

2 Protection of feeders
To summarize:
Use this procedure to determine the cross section of the cable:
1. from Table 10, determine the correction factor k1 according to the insulation
material and the ground temperature;

2. use Table 11, Table 12, Table 13 or the formula for groups of non-similar
cables to determine the correction factor k2 according to the distance
between cables or ducts;

3. from Table 14 determine factor k3 corresponding to the soil thermal resistivity;

4. calculate the value of the current Ib by dividing the load current Ib (or the
rated current of the protective device) by the product of the correction factors
calculated:
Ib I
I b' = = b
k1k2 k 3 k tot
5. from Table 15, determine the cross section of the cable with I0 Ib, according
to the method of installation, the insulation and conductive material and the
number of live conductors;

6. the actual cable current carrying capacity is calculated by.

I z = I 0 k 1k 2 k 3

Table 15: Current carrying capacity of cables buried in the ground

Installation
D
method

Conductor Cu Al
XLPE XLPE
Insulation EPR PVC EPR PVC

Loaded
2 3 2 3 2 3 2 3
conductors
S[mm2]
1.5 26 22 22 18
2.5 34 29 29 24 26 22 22 18.5
4 44 37 38 31 34 29 29 24
6 56 46 47 39 42 36 36 30
10 73 61 63 52 56 47 48 40
16 95 79 81 67 73 61 62 52
25 121 101 104 86 93 78 80 66
35 146 122 125 103 112 94 96 80
50 173 144 148 122 132 112 113 94
1SDC010008F0201

70 213 178 183 151 163 138 140 117

95 252 211 216 179 193 164 166 138
120 287 240 246 203 220 186 189 157
150 324 271 278 230 249 210 213 178
185 363 304 312 258 279 236 240 200
240 419 351 361 297 322 272 277 230
300 474 396 408 336 364 308 313 260

48 ABB SACE - Electrical devices

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2 Protection of feeders

START

selection of wiring systems table 1

erection of wiring systems table 2

Method of installation table 3

Ib

yes Ground temperature

yes
D method? <> k 1 from table 10
20 C?
no
no
yes
k 1 from table 4 Ambient air temperature k1 = 1
<>
30 C?

no
k1 = 1
cables laid directly
yes k 2 ' from table 11
in the ground? (k 2 ''=1)

no
yes yes
for cables? multi-core cable?

no k2 = 1
no
similar no k 2 ' from table 13 k 2 ' from table 12
sections?

yes 1
k 2 '' =
n

yes no more than one yes

k 2 from table 7 multi-core cable? single layer?
cable per conduit?

no yes similar no 1
k 2 '' =
1SDC010009F0201

sections?
n
k 2 from table 6 k 2 from table 5
k 2 ''=1
yes

k 2 '' from table 6

k tot =k 1 *k 2

I' b =I b /k tot k tot =k 1 *k 2 *k 3

k 2 =k 2 '*k 2 ''

table current carrying capacity yes

Thermal resistivity k 3 from table 14
I 0 > I' b <> 2.5 Km/W?

no
k3 = 1

S [mm2 ]
I z = I 0 *k tot

END

ABB SACE - Electrical devices 49

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Note on current carrying capacity tables and loaded conductors
Tables 8, 9 and 15 provide the current carrying capacity of loaded conductors
(current carrying conductors) under normal service conditions.
In single-phase circuits, the number of loaded conductors is two.
In balanced or slightly unbalanced three-phase circuits the number of loaded
conductors is three, since the current in the neutral conductor is negligible.
In three-phase systems with high unbalance, where the neutral conductor in a
multi-core cable carries current as a result of an unbalance in the phase currents
the temperature rise due to the neutral current is offset by the reduction in the
heat generated by one or more of the phase conductors. In this case the
conductor size shall be chosen on the basis of the highest phase current. In all
cases the neutral conductor shall have an adequate cross section.

Effect of harmonic currents on balanced three-phase

systems: reduction factors for harmonic currents in four-
core and five-core cables with four cores carrying current
Where the neutral conductor carries current without a corresponding reduction
in load of the phase conductors, the current flowing in the neutral conductor
shall be taken into account in ascertaining the current-carrying capacity of the
circuit.
This neutral current is due to the phase currents having a harmonic content
which does not cancel in the neutral. The most significant harmonic which
does not cancel in the neutral is usually the third harmonic. The magnitude of
the neutral current due to the third harmonic may exceed the magnitude of the
power frequency phase current. In such a case the neutral current will have a
significant effect on the current-carrying capacity of the cables in the circuit.

N
1SDC010007F0001

50 ABB SACE - Electrical devices

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2 Protection of feeders
Equipment likely to cause significant harmonic currents are, for example,
fluorescent lighting banks and dc power supplies such as those found in
computers (for further information on harmonic disturbances see the IEC 61000).
The reduction factors given in Table 16 only apply in the balanced three-phase
circuits (the current in the fourth conductor is due to harmonics only) to cables
where the neutral conductor is within a four-core or five-core cable and is of the
same material and cross-sectional area as the phase conductors. These
reduction factors have been calculated based on third harmonic currents. If
significant, i.e. more than 10 %, higher harmonics (e.g. 9th, 12th, etc.) are
expected or there is an unbalance between phases of more than 50 %, then
lower reduction factors may be applicable: these factors can be calculated only
by taking into account the real shape of the current in the loaded phases.
Where the neutral current is expected to be higher than the phase current then
the cable size should be selected on the basis of the neutral current.
Where the cable size selection is based on a neutral current which is not
significantly higher than the phase current, it is necessary to reduce the tabulated
current carrying capacity for three loaded conductors.
If the neutral current is more than 135 % of the phase current and the cable size
is selected on the basis of the neutral current, then the three phase conductors
will not be fully loaded. The reduction in heat generated by the phase conductors
offsets the heat generated by the neutral conductor to the extent that it is not
necessary to apply any reduction factor to the current carrying capacity for
three loaded conductors.

Table 16: Reduction factors for harmonic currents in four-core and

five-core cables
Third harmonic content
of phase current Reduction factor
Current to take in Current to take in
% Size selection is account for the Size selection is account for the
based on phase cable selection based on neutral cable selection
current Ib current Ib

Ib
0 15 1 I 'b = - -
k tot
Ib
15 33 0.86 I 'b = -
k tot . 0.86 -
IN
33 45 - - 0.86 I'b =
0.86

> 45 - - 1 I 'b = I N

Ib
Where IN is the current flowing in the neutral calculated as follows: IN = .3 . k
k tot III

Ib is the load current;

ktot is the total correction factor;
kIII is the third harmonic content of phase current;

ABB SACE - Electrical devices 51

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Example of cable dimensioning in a balanced three-
phase circuit without harmonics
Dimensioning of a cable with the following characteristics:
conductor material: : copper

insulation material: : PVC

type of cable: : multi-core

installation: : cables bunched on horizontal

perforated tray

load current: : 100 A

Installation conditions:
ambient temperature: : 40 C

adjacent circuits with a) three-phase circuit consisting of 4

single-core cables, 4x50 mm2;

b) three-phase circuit consisting of one

multi-core cable, 1x(3x50) mm2;

c) three-phase circuit consisting of 9

single-core (3 per phase) cables,
9x95 mm2;

d) single-phase circuit consisting of 2

single-core cables, 2x70 mm2.

a c
b

d
1SDC010008F0001

52 ABB SACE - Electrical devices

 2.2 Installation and dimensioning of cables

2 Protection of feeders
Procedure:
Type of installation
In Table 3, it is possible to find the reference number of the installation and the
method of installation to be used for the calculations. In this example, the
reference number is 31, which corresponds to method E (multi-core cable on
tray).

Correction factor of temperature k1

From Table 4, for a temperature of 40 C and PVC insulation material, k1 =
0.87.
k 1 = 0.87
Correction factor for adjacent cables k2
For the multi-core cables grouped on the perforated tray see Table 5.
As a first step, the number of circuits or multi-core cables present shall be
determined; given that:

each circuit a), b) and d) constitute a separate circuit;

circuit c) consists of three circuits, since it is composed by three cables in
parallel per phase;
the cable to be dimensioned is a multi-core cable and therefore constitutes a
single circuit;
the total number of circuits is 7.
Referring to the row for the arrangement (cables bunched) and to the column
for the number of circuits (7)

k 2 = 0.54

After k1 and k2 have been determined, Ib is calculated by:

Ib 100
I 'b = = = 212.85A
k1k2 0.87. 0.54

From Table 8, for a multi-core copper cable with PVC insulation, method of
installation E, with three loaded conductors, a cross section with current carrying
capacity of I0 Ib = 212.85 A, is obtained. A 95 mm2 cross section cable can
carry, under Standard reference conditions, 238 A.
The current carrying capacity, according to the actual conditions of installation,
is Iz = 238 . 0.87. 0.54 = 111.81 A

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Example of dimensioning a cable in a balanced three-
phase circuit with a significant third-harmonic content
Dimensioning of a cable with the following characteristics:
conductor material: : copper

insulation material: : PVC

type of cable: : multi-core

installation: : layer on horizontal perforated tray

load current: : 115 A

Installation conditions:
ambient temperature: : 30 C

no adjacent circuits.

Procedure:
Type of installation
On Table 3, it is possible to find the reference number of the installation and the
method of installation to be used for the calculations. In this example, the
reference number is 31, which corresponds to method E (multi-core cable on
tray).

Temperature correction factor k1

From Table 4, for a temperature of 30 C and PVC insulation material

k1 = 1

Correction factor for adjacent cables k2

As there are no adjacent cables, so

k2 = 1
After k1 and k2 have been determined, Ib is calculated by:

Ib
I 'b = = 115 A
k1k 2

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If no harmonics are present, from Table 8, for a multi-core copper cable with
PVC insulation, method of installation E, with three loaded conductors, a cross
section with current carrying capacity of I0 Ib = 115 A, is obtained. A 35 mm2
cross section cable can carry, under Standard reference conditions, 126 A.
The current carrying capacity, according to the actual conditions of installation,
is still 126 A, since the value of factors k1 and k2 is 1.

The third harmonic content is assumed to be 28%.

Table 16 shows that for a third harmonic content of 28% the cable must be
dimensioned for the current that flows through the phase conductors, but a
reduction factor of 0.86 must be applied. The current Ib becomes:

Ib 115
I 'b = = = 133.7 A
k1 . k 2 . 0.86 0.86

From Table 8, a 50 mm2 cable with carrying capacity of 153 A shall be selected.

If the third harmonic content is 40 %, Table 16 shows that the cable shall be
dimensioned according to the current of the neutral conductor and a reduction
factor of 0.86 must be applied.
The current in the neutral conductor is:

Ib . .
IN = 3 k III = 115. 3 . 0.4 = 138 A
ktot

and the value of current Ib is:

IN 138
I 'b = = = 160.5 A
0.86 0.86

From Table 8, a 70 mm2 cable with 196 A current carrying capacity shall be
selected.
If the third harmonic content is 60 %, Table 16 shows that the cable shall be
dimensioned according to the current of the neutral conductor, but a reduction
factor of 1 must be applied.
The current in the neutral conductor is:

Ib . .
IN = 3 kIII = 115. 3 . 0.6 = 207A
ktot

and current Ib is:

I 'b = I N = 207A

From Table 8, a 95 mm2 cable with current carrying capacity of 238 A must be
selected.

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2.2.2 Voltage drop
In an electrical installation it is important to evaluate voltage drops from the
point of supply to the load.
The performance of a device may be impaired if supplied with a voltage different
from its rated voltage. For example:
motors: the torque is proportional to the square of the supply voltage; therefore,
if the voltage drops, the starting torque shall also decrease, making it more
difficult to start up motors; the maximum torque shall also decrease;
incandescent lamps: the more the voltage drops the weaker the beam
becomes and the light takes on a reddish tone;
discharge lamps: in general, they are not very sensitive to small variations in
voltage, but in certain cases, great variation may cause them to switch off;
electronic appliances: they are very sensitive to variations in voltage and that
is why they are fitted with stabilizers;
electromechanical devices: the reference Standard states that devices such
as contactors and auxiliary releases have a minimum voltage below which
their performances cannot be guaranteed. For a contactor, for example, the
holding of the contacts becomes unreliable below 85% of the rated voltage.

To limit these problems the Standards set the following limits:

IEC 60364-5-52 Electrical installations of buildings. Selection and erection

of electrical equipment - Wiring systems Clause 525 states that in the
absence of other considerations it is recommended that in practice the voltage
drop between the origin of consumers installation and the equipment should
not be greater than 4% of the rated voltage of the installation. Other
considerations include start-up time for motors and equipment with high inrush
current. Temporary conditions such as voltage transients and voltage variation
due to abnormal operation may be disregarded.
IEC 60204-1Safety of machinery Electrical equipment of machines General
requirements Clause 13.5 recommends that: the voltage drop from the
point of supply to the load shall not exceed 5% of the rated voltage under
normal operating conditions.
IEC 60364-7-714 Electrical installations of buildings - Requirements for special
installations or locations - External lighting installations Clause 714.512
requires that the voltage drop in normal service shall be compatible with the
conditions arising from the starting current of the lamps.

56 ABB SACE - Electrical devices

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Voltage drop calculation

For an electrical conductor with impedance Z, the voltage drop is calculated by
the following formula:
L
U = kZIb = kIb ( r cos + x sin ) [V] (1)
n
where
k is a coefficient equal to:
- 2 for single-phase and two-phase systems;
- for three-phase systems;
Ib [A] is the load current; if no information are available, the cable carrying
capacity Iz shall be considered;
L [km] is the length of the conductor;
n is the number of conductors in parallel per phase;
r [/km] is the resistance of the single cable per kilometre;
x [/km] is the reactance of the single cable per kilometre;

cos is the power factor of the load: sin = 1 - cos 2 .

Normally, the percentage value in relation to the rated value Ur is calculated by:
U
u% = 100 (2)
Ur

Resistance and reactance values per unit of length are set out on the following
table by cross-sectional area and cable formation, for 50 Hz; in case of 60 Hz,
the reactance value shall be multiplied by 1.2.

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Table 1: Resistance and reactance per unit of length of copper cables

single-core cable two-core/three-core cable

S r[/km] x[/km] r[/km] x[/km]
[mm2] @ 80 [C] @ 80 [C]
1.5 14.8 0.168 15.1 0.118
2.5 8.91 0.156 9.08 0.109
4 5.57 0.143 5.68 0.101
6 3.71 0.135 3.78 0.0955
10 2.24 0.119 2.27 0.0861
16 1.41 0.112 1.43 0.0817
25 0.889 0.106 0.907 0.0813
35 0.641 0.101 0.654 0.0783
50 0.473 0.101 0.483 0.0779
70 0.328 0.0965 0.334 0.0751
95 0.236 0.0975 0.241 0.0762
120 0.188 0.0939 0.191 0.074
150 0.153 0.0928 0.157 0.0745
185 0.123 0.0908 0.125 0.0742
240 0.0943 0.0902 0.0966 0.0752
300 0.0761 0.0895 0.078 0.075

Table 2: Resistance and reactance per unit of length of aluminium

cables
single-core cable two-core/three-core cable
S r[/km] x[/km] r[/km] x[/km]
[mm2] @ 80 [C] @ 80 [C]
1.5 24.384 0.168 24.878 0.118
2.5 14.680 0.156 14.960 0.109
4 9.177 0.143 9.358 0.101
6 6.112 0.135 6.228 0.0955
10 3.691 0.119 3.740 0.0861
16 2.323 0.112 2.356 0.0817
25 1.465 0.106 1.494 0.0813
35 1.056 0.101 1.077 0.0783
50 0.779 0.101 0.796 0.0779
70 0.540 0.0965 0.550 0.0751
95 0.389 0.0975 0.397 0.0762
120 0,310 0.0939 0.315 0.074
150 0.252 0.0928 0.259 0.0745
185 0.203 0.0908 0.206 0.0742
240 0.155 0.0902 0.159 0.0752
300 0.125 0.0895 0.129 0.075

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The following tables show the Ux [V/(A.km)] values by cross section and
formation of the cable according to the most common cos values.

Table 3: Specific voltage drop at cos = 1 for copper cables

cos = 1
single-core cable two-core cable three-core cable
S[mm2] single-phase three-phase single-phase three-phase
1.5 29.60 25.63 30.20 26.15
2.5 17.82 15.43 18.16 15.73
4 11.14 9.65 11.36 9.84
6 7.42 6.43 7.56 6.55
10 4.48 3.88 4.54 3.93
16 2.82 2.44 2.86 2.48
25 1.78 1.54 1.81 1.57
35 1.28 1.11 1.31 1.13
50 0.95 0.82 0.97 0.84
70 0.66 0.57 0.67 0.58
95 0.47 0.41 0.48 0.42
120 0.38 0.33 0.38 0.33
150 0.31 0.27 0.31 0.27
185 0.25 0.21 0.25 0.22
240 0.19 0.16 0.19 0.17
300 0.15 0.13 0.16 0.14

Table 4: Specific voltage drop at cos = 0.9 for copper cables

cos = 0.9
single-core cable two-core cable three-core cable
S[mm2] single-phase three-phase single-phase three-phase
1.5 26.79 23.20 27.28 23.63
2.5 16.17 14.01 16.44 14.24
4 10.15 8.79 10.31 8.93
6 6.80 5.89 6.89 5.96
10 4.14 3.58 4.16 3.60
16 2.64 2.28 2.65 2.29
25 1.69 1.47 1.70 1.48
35 1.24 1.08 1.25 1.08
50 0.94 0.81 0.94 0.81
70 0.67 0.58 0.67 0.58
95 0.51 0.44 0.50 0.43
120 0.42 0.36 0.41 0.35
150 0.36 0.31 0.35 0.30
185 0.30 0.26 0.29 0.25
240 0.25 0.22 0.24 0.21
300 0.22 0.19 0.21 0.18

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Table 5: Specific voltage drop at cos = 0.85 for copper cables
cos = 0.85
single-core cable two-core cable three-core cable
S[mm2] single-phase three-phase single-phase three-phase
1.5 25.34 21.94 25.79 22.34
2.5 15.31 13.26 15.55 13.47
4 9.62 8.33 9.76 8.45
6 6.45 5.59 6.53 5.65
10 3.93 3.41 3.95 3.42
16 2.51 2.18 2.52 2.18
25 1.62 1.41 1.63 1.41
35 1.20 1.04 1.19 1.03
50 0.91 0.79 0.90 0.78
70 0.66 0.57 0.65 0.56
95 0.50 0.44 0.49 0.42
120 0.42 0.36 0.40 0.35
150 0.36 0.31 0.35 0.30
185 0.30 0.26 0.29 0.25
240 0.26 0.22 0.24 0.21
300 0.22 0.19 0.21 0.18

Table 6: Specific voltage drop at cos = 0.8 for copper cables

cos = 0.8
single-core cable two-core cable three-core cable
S[mm2] single-phase three-phase single-phase three-phase
1.5 23.88 20.68 24.30 21.05
2.5 14.44 12.51 14.66 12.69
4 9.08 7.87 9.21 7.98
6 6.10 5.28 6.16 5.34
10 3.73 3.23 3.74 3.23
16 2.39 2.07 2.39 2.07
25 1.55 1.34 1.55 1.34
35 1.15 0.99 1.14 0.99
50 0.88 0.76 0.87 0.75
70 0.64 0.55 0.62 0.54
95 0.49 0.43 0.48 0.41
120 0.41 0.36 0.39 0.34
150 0.36 0.31 0.34 0.29
185 0.31 0.26 0.29 0.25
240 0.26 0.22 0.24 0.21
300 0.23 0.20 0.21 0.19

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Table 7: Specific voltage drop at cos=0.75 for copper cables
cos = 0.75
single-core cable two-core cable three-core cable
S[mm2] single-phase three-phase single-phase three-phase
1.5 22.42 19.42 22.81 19.75
2.5 13.57 11.75 13.76 11.92
4 8.54 7.40 8.65 7.49
6 5.74 4.97 5.80 5.02
10 3.52 3.05 3.52 3.05
16 2.26 1.96 2.25 1.95
25 1.47 1.28 1.47 1.27
35 1.10 0.95 1.08 0.94
50 0.84 0.73 0.83 0.72
70 0.62 0.54 0.60 0.52
95 0.48 0.42 0.46 0.40
120 0.41 0.35 0.38 0.33
150 0.35 0.31 0.33 0.29
185 0.30 0.26 0.29 0.25
240 0.26 0.23 0.24 0.21
300 0.23 0.20 0.22 0.19

Table 8: Specific voltage drop at cos = 1 for aluminium cables

cos = 1
single-core cable two-core cable three-core cable
S[mm2] single-phase three-phase single-phase three-phase
1.5 48.77 42.23 49.76 43.09
2.5 29.36 25.43 29.92 25.91
4 18.35 15.89 18.72 16.21
6 12.22 10.59 12.46 10.79
10 7.38 6.39 7.48 6.48
16 4.65 4.02 4.71 4.08
25 2.93 2.54 2.99 2.59
35 2.11 1.83 2.15 1.87
50 1.56 1.35 1.59 1.38
70 1.08 0.94 1.10 0.95
95 0.78 0.67 0.79 0.69
120 0.62 0.54 0.63 0.55
150 0.50 0.44 0.52 0.45
185 0.41 0.35 0.41 0.36
240 0.31 0.27 0.32 0.28
300 0.25 0.22 0.26 0.22

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Table 9: Specific voltage drop at cos = 0.9 for aluminium cables
cos = 0.9
single-core cable two-core cable three-core cable
S[mm2] single-phase three-phase single-phase three-phase
1.5 44.04 38.14 44.88 38.87
2.5 26.56 23.00 27.02 23.40
4 16.64 14.41 16.93 14.66
6 11.12 9.63 11.29 9.78
10 6.75 5.84 6.81 5.89
16 4.28 3.71 4.31 3.73
25 2.73 2.36 2.76 2.39
35 1.99 1.72 2.01 1.74
50 1.49 1.29 1.50 1.30
70 1.06 0.92 1.06 0.91
95 0.78 0.68 0.78 0.68
120 0.64 0.55 0.63 0.55
150 0.53 0.46 0.53 0.46
185 0.44 0.38 0.44 0.38
240 0.36 0.31 0.35 0.30
300 0.30 0.26 0.30 0.26

Table 10: Specific voltage drop at cos = 0.85 for aluminium cables
cos = 0.85
single-core cable two-core cable three-core cable
S[mm2] single-phase three-phase single-phase three-phase
1.5 41.63 36.05 42.42 36.73
2.5 25.12 21.75 25.55 22.12
4 15.75 13.64 16.02 13.87
6 10.53 9.12 10.69 9.26
10 6.40 5.54 6.45 5.58
16 4.07 3.52 4.09 3.54
25 2.60 2.25 2.63 2.27
35 1.90 1.65 1.91 1.66
50 1.43 1.24 1.43 1.24
70 1.02 0.88 1.01 0.88
95 0.76 0.66 0.76 0.65
120 0.63 0.54 0.61 0.53
150 0.53 0.46 0.52 0.45
185 0.44 0.38 0,43 0.37
240 0.36 0.31 0.35 0.30
300 0.31 0.27 0.30 0.26

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Table 11: Specific voltage drop at cos = 0.8 for aluminium cables
cos = 0.8
single-core cable two-core cable three-core cable
S[mm2] single-phase three-phase single-phase three-phase
1.5 39.22 33.96 39.95 34.59
2.5 23.67 20.50 24.07 20.84
4 14.85 12.86 15.09 13.07
6 9.94 8.61 10.08 8.73
10 6.05 5.24 6.09 5.27
16 3.85 3.34 3.87 3.35
25 2.47 2.14 2.49 2.16
35 1.81 1.57 1.82 1.57
50 1.37 1.18 1.37 1.18
70 0.98 0.85 0.97 0.84
95 0.74 0.64 0.73 0.63
120 0.61 0.53 0.59 0.51
150 0.51 0.45 0.50 0.44
185 0.43 0.38 0.42 0.36
240 0.36 0.31 0.34 0.30
300 0.31 0.27 0.30 0.26

Table 12: Specific voltage drop at cos = 0.75 for aluminium cables
cos = 0.75
single-core cable two-core cable three-core cable
S[mm2] single-phase three-phase single-phase three-phase
1.5 36.80 31.87 37.47 32.45
2.5 22.23 19.25 22.58 19.56
4 13.95 12.08 14.17 12.27
6 9.35 8.09 9.47 8.20
10 5.69 4.93 5.72 4.96
16 3.63 3.15 3.64 3.15
25 2.34 2.02 2.35 2.03
35 1.72 1.49 1.72 1.49
50 1.30 1.13 1.30 1.12
70 0.94 0.81 0.92 0.80
95 0.71 0.62 0.70 0.60
120 0.59 0.51 0.57 0.49
150 0.50 0.43 0.49 0.42
185 0.42 0.37 0.41 0.35
240 0.35 0.31 0.34 0.29
300 0.31 0.27 0.29 0.25

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Example 1
To calculate a voltage drop on a three-phase cable with the following
specifications:
rated voltage: 400 V;
cable length: 25 m;
cable formation: single-core copper cable, 3x50 mm2;
load current Ib: 100 A;
power factor cos: 0.9.

From Table 4, for a 50 mm2 single-core cable it is possible to read that a Ux

voltage drop corresponds to 0.81 V/(Akm). By multiplying this value by the
length in km and by the current in A, it results:

U = U x . I b . L = 0.81 . 100 . 0.025 = 2.03 V

which corresponds to this percentage value:

U . 2.03 .
u% = 100 = 100 = 0.51%
Ur 400

Example 2
To calculate a voltage drop on a three-phase cable with the following
specifications:
rated voltage: 690 V;
cable length: 50 m;
cable formation: multi-core copper cable, 2x(3x10) mm2;
load current Ib: 50 A;
power factor cos: 0.85.
From Table 5, for a multi-core 10 mm2 cable it is possible to read that Ux
voltage drop corresponds to 3.42 V/(Akm). By multiplying this value by the
length in km and by the current in A, and by dividing it by the number of cables
in parallel, it results:
L 0.05
U = U x . I b . = 3.42. 50 . = 4.28 V
2 2

which corresponds to this percentage value:

U . 4.28 .
u% = 100 = 100 = 0.62%
Ur 690

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Method for defining the cross section of the conductor according to
voltage drop in the case of long cables
In the case of long cables, or if particular design specifications impose low
limits for maximum voltage drops, the verification using as reference the cross
section calculated on the basis of thermal considerations (calculation according
to chapter 2.2.1 Current carrying capacity and methods of installation) may
have a negative result.
To define the correct cross section, the maximum Uxmax value calculated by
using the formula:
u%.U r
U x max = (3)
100. I b . L

is compared with the corresponding values on Tables 412 by choosing the

smallest cross section with a Ux value lower than Uxmax.

Example:
Supply of a three-phase load with Pu = 35 kW (Ur=400 V, fr= 50 Hz, cos=0.9)
with a 140 m cable installed on a perforated tray, consisting of a multi-core
copper cable with EPR insulation.
Maximum permitted voltage drop 2%.

Load current Ib is:

Pu 35000
Ib = = = 56 A
3 .U r . cos 3 . 400. 0.9

The Table 8 of Chapter 2.2.1 shows S = 10 mm2.

From Table 4, for the multi-core 10 mm2 cable it is possible to read that the
voltage drop per A and per km is 3.60 V/(Akm). By multiplying this value by the
length in km and by the current in A, it results:

U = 3.60. I b . L = 3.6 . 56. 0.14 = 28.2 V

which corresponds to this percentage value:

U . 28.2 .
u% = 100 = 100 = 7.05%
Ur 400

This value is too high.

Formula (3) shows:

u% .U r 2% . 400
U x max = = = 1.02 V/(A . km)
100 . I b . L 100 . 56 . 0.14

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From Table 4 a cross section of 50 mm2 can be chosen.
For this cross section Ux = 0.81< 1.02 V/(Akm).
By using this value it results:
U = U x . I b . L = 0.81. 56 . 0.14 = 6.35 V

This corresponds to a percentage value of:

U . 6.35 .
u% = 100 = 100 = 1.6%
Ur 400

2.2.3 Joule-effect losses

Joule-effect losses are due to the electrical resistance of the cable.
The lost energy is dissipated in heat and contributes to the heating of the
conductor and of the environment.
A first estimate of three-phase losses is:
3. r . I b2 . L
Pj = [W]
1000
whereas single-phase losses are:

2 . r . I b2 . L
Pj = [W]
1000
where:
Ib is the load current [A];
r is the phase resistance per unit of length of the cable at 80 C [/km] (see
Table 1);
L is the cable length [m].

Table 1: Resistance values [/km] of single-core and multi-core

cables in copper and aluminium at 80 C
Single-core cable Two-core/three-core cable
S
[mm2] Cu AI Cu AI
1.5 14.8 24.384 15.1 24.878
2.5 8.91 14.680 9.08 14.960
4 5.57 9.177 5.68 9.358
6 3.71 6.112 3.78 6.228
10 2.24 3.691 2.27 3.740
16 1.41 2.323 1.43 2.356
25 0.889 1.465 0.907 1.494
35 0.641 1.056 0.654 1.077
50 0.473 0.779 0.483 0.796
70 0.328 0.540 0.334 0.550
95 0.236 0.389 0.241 0.397
120 0.188 0.310 0.191 0.315
150 0.153 0.252 0.157 0.259
185 0.123 0.203 0.125 0.206
240 0.0943 0.155 0.0966 0.159
300 0.0761 0.125 0.078 0.129

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2.3 Protection against overload

The Standard IEC 60364-4-43 Electrical installation of buildings - Protection

against overcurrent specifies coordination between conductors and overload
protective devices (normally placed at the beginning of the conductor to be
protected) so that it shall satisfy the two following conditions:

I b In I z (1)
I2 1.45 . Iz (2)
Where:
Ib is the current for which the circuit is dimensioned;
Iz is the continuous current carrying capacity of the cable;
In is the rated current of the protective device; for adjustable protective releases,
the rated current In is the set current;
I2 is the current ensuring effective operation in the conventional time of the
protective device.

Ib Iz 1.45Iz

1SDC010009F0001
In I2

According to condition (1) to correctly choose the protective device, it is

necessary to check that the circuit-breaker has a rated (or set) current that is:
higher than the load current, to prevent unwanted tripping;
lower than the current carrying capacity of the cable, to prevent cable overload.
The Standard allows an overload current that may be up to 45% greater than
the current carrying capacity of the cable but only for a limited period
(conventional trip time of the protective device).
The verification of condition (2) is not necessary in the case of circuit-breakers
because the protective device is automatically tripped if:
I2 = 1.3In for circuit-breakers complying with IEC 60947-2 (circuit-breakers
for industrial use);
I2 = 1.45In for circuit-breakers complying with IEC 60898 (circuit-breakers
for household and similar installations).
Therefore, for circuit-breakers, if In Iz, the formula I2 1.45Iz will also be
verified.
When the protective device is a fuse, it is also essential to check formula (2)
because IEC 60269-2-1 on Low-voltage fuses states that a 1.6In current
must automatically melt the fuse. In this case, formula (2) becomes 1.6In 1.45Iz
or In 0.9Iz.
To sum up: to carry out protection against overload by a fuse, the following

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To summarize: to carry out by a fuse protection against overload, the following
must be achieved:

Ib In 0.9 .Iz

and this means that the cable is not fully exploited.

1SDC010010F0001
Ib Iz

In
Circuit-breaker: choice of rated current

1SDC010011F0001
Ib 0.9 Iz

In
Fuse: choice of rated current

Where the use of a single conductor per phase is not feasible, and the currents
in the parallel conductors are unequal, the design current and requirements for
overload protection for each conductor shall be considered individually.

Examples
Example 1
Load specifications
Pr = 70 kW; Ur = 400 V; cos = 0.9; three-phase load so Ib = 112 A

Cable specifications

Iz = 134 A

Protective device specifications

T1B160 TMD In 125; set current I1 = 125 A

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 2.3 Protection against overload

2 Protection of feeders
Example 2
Load specifications
Pr = 80 kW; cos = 0.9; Ur = 400 V; three-phase load so Ib = 128 A

Cable specifications

Iz = 171 A

Protective device specifications

T2N160 PR221DS-LS In 160; set current I1 = 0.88 x In = 140.8 A

Example 3
Load specifications
Pr = 100 kW; cos = 0.9; Ur = 400 V ; three-phase load so Ib = 160 A

Cable specifications

Iz = 190 A

Protective device specifications

T3N250 TMD R200 In 200; set current I1 = 0.9 x In = 180 A

Example 4
Load specifications
Pr = 25 kW; cos = 0.9; Ur = 230 V ; single-phase load so Ib = 121 A

Cable specifications
Iz = 134 A

Protective device specifications

T1B160 1P TMF In 125

ABB SACE - Electrical devices 69

 2 Protection of feeders

2.4 Protection against short-circuit

A cable is protected against short-circuit if the specific let-through energy of

the protective device (I2t) is lower or equal to the withstood energy of the cable
(k2S2):

I2t k 2S2 (1)

where
I2t is the specific let-through energy of the protective device which can be
read on the curves supplied by the manufacturer (see Electrical installation
handbook, Vol. 1, Chapter 3.4 Specific let-through energy curves) or from a
direct calculation in the case of devices that are not limiting and delaying;
S is the cable cross section [mm2]; in the case of conductors in parallel it is
the cross section of the single conductor;
k is a factor that depends on the cable insulating and conducting material.
The values of the most common installations are shown in Table 1; for a more
detailed calculation, see Annex D.

Table 1: Values of k for phase conductor

Conductor insulation

PVC PVC EPR Rubber Mineral

300 mm2 >300 mm2 XLPE 60 C
PVC Bare
Initial temperature C 70 70 90 60 70 105
Final temperature C 160 140 250 200 160 250
Material of conductor:
Copper 115 103 143 141 115 135/115 a
Aluminium 76 68 94 93 - -
tin-soldered joints 115 - - - - -
in copper conductors
a
This value shall be used for bare cables exposed to touch.

NOTE 1 Other values of k are under consideration for.

- small conductors (particularly for cross section less than 10 mm2);
- duration of short-circuit exceeding 5 s;
- other types of joints in conductors;
1SDC010010F0201

- bare conductors.
NOTE 2 The nominal current of the short-circuit protective device may be greater than the current carrying
capacity of the cable.

NOTE 3 The above factors are based on IEC 60724.

70 ABB SACE - Electrical devices

 2.4 Protection against short-circuit

2 Protection of feeders
Table 2 shows the maximum withstood energy for cables according to the
cross section, the conductor material and the type of insulation, which are
calculated by using the parameters of Table 1.

Table 2: Maximum withstood energy for cables k2 S2 [(kA)2 s]

Cross section [mm2 ]

Cable k 1.5 2.5 4 6 10 16 25 35
-2 -2 -1 -1 1
Cu 115 2.9810 8.2710 2.1210 4.7610 1.32 3.39 8.27 1.6210
PVC -2 -2 -2 -1 -1
Al 76 1.3010 3.6110 9.2410 2.0810 5.7810 1.48 3.61 7.08
-2 -1 -1 -1 1 1
Cu 143 4.6010 1.2810 3.2710 7.3610 2.04 5.23 1.2810 2.5110
EPR/XLPE -2 -2 -1 -1 -1 1
Al 94 1.9910 5.5210 1.4110 3.1810 8.8410 2.26 5.52 1.0810
-2 -1 -1 -1 1 1
Cu 141 4.4710 1.2410 3.1810 7.1610 1.99 5.09 1.2410 2.4410
Rubber -2 -2 -1 -1 -1 1
Al 93 1.9510 5.4110 1.3810 3.1110 8.6510 2.21 5.41 1.0610

Cross section [mm2 ]

Cable k 50 70 95 120 150 185 240 300
1 1 2 2 2 2 2 3
Cu 115 3.3110 6.4810 1.1910 1.9010 2.9810 4.5310 7.6210 1.1910
PVC

1SDC010002F0901
1 1 1 1 2 2 2 2
Al 76 1.4410 2.8310 5.2110 8.3210 1.3010 1.9810 3.3310 5.2010
1 1 1 2 2 2 3 3
Cu 143 5.1110 1.0010 1.8510 2.9410 4.6010 7.0010 1.1810 1.8410
EPR/XLPE 1 1 1 2 2 2 2 2
Al 94 2.2110 4.3310 7.9710 1.2710 1.9910 3.0210 5.0910 7.9510
1 1 1 2 2 2 3 3
Cu 141 4.9710 9.7410 1.7910 2.8610 4.4710 6.8010 1.1510 1.7910
G2 1 1 1 2 2 2 2 2
Al 93 2.1610 4.2410 7.8110 1.2510 1.9510 2.9610 4.9810 7.7810

The formula (1) must be verified along the whole length of the cable. Due to the
shape of the specific let-through energy curve of a circuit breaker, it is generally
sufficient to verify formula (1) only for the maximum and minimum short-circuit
current that may affect the cable. The maximum value is normally the value of
the three-phase short-circuit current at the beginning of the line, while the
minimum value is the value of the phase to neutral short-circuit current (phase
to phase if the neutral conductor is not distributed) or phase to earth at the end
of the cable.

ABB SACE - Electrical devices 71

 2.4 Protection against short-circuit

2 Protection of feeders
[(KA)2s] 102

10

10-1

10-2

1SDC010011F0001
10-3

10-1 1 10 [KA]

This verification can be simplified by comparing only the let-through energy

value of the circuit-breaker at the maximum short-circuit current with the
withstood energy of the cable and by ensuring that the circuit breaker trips
instantaneously at the minimum short-circuit current: the threshold of the short-
circuit protection (taking into consideration also the tolerances) shall therefore
be lower than the minimum short-circuit current at the end of the conductor.

72 ABB SACE - Electrical devices

 2.4 Protection against short-circuit

2 Protection of feeders
Calculation of short-circuit current at end of the conductor
Minimum short-circuit current can be calculated by the following approximate
formulas:

0.8 . Ur . k sec . k par

Ikmin = with non-distributed neutral conductor (2.1)
2L
1.5 . .
S
0.8 . U . k . k
0 sec par
Ikmin = with distributed neutral conductor (2.2)
L
1.5 . . (1 + m) .
S
where:
Ikmin is the minimum value of the prospective short-circuit current [kA];
Ur is the supply voltage [V];
U0 is the phase to earth supply voltage [V];
is the resistivity at 20 C of the material of the conductors in mm2/m and is:
- 0.018 for copper;
- 0.027 for aluminium;
L is the length of the protected conductor [m];
S is the cross section of the conductor [mm2];
ksec is the correction factor which takes into account the reactance of the
cables with cross section larger than 95 mm2:

S[mm2] 120 150 180 240 300

ksec 0.9 0.85 0.80 0.75 0.72

kpar is the correcting coefficient for conductors in parallel:

number of parallel
conductors 2 3 4 5
kpar* 2 2.7 3 3.2
*kpar = 4 (n-1)/n where: n = number of conductors in parallel per phase

m is the ratio between the resistances of the neutral conductor and the phase
conductor (if they are made of the same material m is the ratio between the
cross section of the phase conductor and the cross section of the neutral
conductor).
After calculating the minimum short-circuit current, verify that
Ikmin >1.2 . I3 (3)
where:
I3 is the current that trips the magnetic protection of the circuit-breaker;
1.2 is the tolerance at the trip threshold.

ABB SACE - Electrical devices 73

 2.4 Protection against short-circuit

2 Protection of feeders
Example
U Ur = 400 V
Ik = 30 kA
Choice of CB1
CB1
System data:
T1N160 In160
Rated voltage 400 V
Ik = 30 kA
Cable Section 50 mm2

Cable data:
PVC Cu L = 150 m

1SDC010011F0201
Insulated copper conductor in PVC
Length = 150 m Iz = 134.0 A
S = 50 mm2
Iz = 134 A
L
Protection against short-circuit at the beginning of the conductor
T1N160 In160 (breaking capacity 36 kA@400 V)
I2t (@30 kA) = 7.5 10-1 (kA)2s (for the curves of specific let-through energy, see
Volume 1, Chapter 3.4)
k2S2 = 1152 502 = 3.31.101 (kA)2s
The cable is therefore protected against short-circuit at the beginning of the
conductor.

Protection against short-circuit at end of the conductor

The minimum short-circuit current at end of the conductor (ksec=1 and kpar=1) is:
0.8 . U . k sec . k par
Ikmin = = 1.98 kA
2L
1.5 . .
S
The magnetic threshold of the circuit breaker T1N160 In160 is set at 1600 A. If
tolerance is 20%, the circuit breaker shall definitely trip if the values exceed
1920 A; the cable is therefore fully protected against short-circuit.

Maximum protected length

The formula (3), when solved for the length, enables the maximum length
protected by the protective device to be obtained for a precise instantaneous
trip threshold. In Table 3, the maximum protected length can be identified for a
given cross section of the cable and for the setting threshold of the instantaneous
protection of the circuit breaker against short-circuit:
- three-phase system, 400 V rated voltage;
- non-distributed neutral;
- copper conductor with resistivity equal to 0.018 mm2/m.
The values on the table below take into account the 20% tolerance coefficient
for the magnetic trip value, the increase in cable resistivity due to heating caused
by the short-circuit current and the reduction of voltage due to the fault.
The correction factors shown after the table must be applied if the system
conditions are different from the reference conditions.

74 ABB SACE - Electrical devices

 2.4 Protection against short-circuit

2 Protection of feeders
Table 3: Maximum protected length
section [mm2]
I3[A] 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300
20 370 617
30 246 412 658
40 185 309 494 741
50 148 247 395 593
60 123 206 329 494
70 105 176 282 423 705
80 92 154 246 370 617
90 82 137 219 329 549
100 74 123 197 296 494 790
120 61 102 164 246 412 658
140 52 88 141 211 353 564
150 49 82 131 197 329 527
160 46 77 123 185 309 494 772
180 41 68 109 164 274 439 686
200 37 61 98 148 247 395 617
220 33 56 89 134 224 359 561 786
250 29 49 79 118 198 316 494 691
280 26 44 70 105 176 282 441 617
300 24 41 65 98 165 263 412 576
320 23 38 61 92 154 247 386 540 772
350 21 35 56 84 141 226 353 494 705
380 19 32 52 78 130 208 325 455 650
400 18 30 49 74 123 198 309 432 617
420 17 29 47 70 118 188 294 412 588
450 16 27 43 65 110 176 274 384 549 768
480 15 25 41 61 103 165 257 360 514 720
500 14 24 39 59 99 158 247 346 494 691
520 14 23 38 57 95 152 237 332 475 665
550 13 22 35 53. 90 144 224 314 449 629
580 12 21 34 51 85 136 213 298 426 596 809
600 12 20 32 49 82 132 206 288 412 576 782
620 11 19 31 47 80 127 199 279 398 558 757
650 11 19 30 45 76 122 190 266 380 532 722
680 10 18 29 43 73 116 182 254 363 508 690
700 10 17 28 42 71 113 176 247 353 494 670 847
750 16 26 39 66 105 165 230 329 461 626 790 840
800 15 24 37 62 99 154 216 309 432 586 667 787
850 14 23 34 58 93 145 203 290 407 552 627 741
900 13 21 32 55 88 137 192 274 384 521 593 700
950 13 20 31 52 83 130 182 260 364 494 561 663
1000 12 19 29 49 79 123 173 247 346 469 533 630 731
1250 15 23 40 63 99 138 198 277 375 427 504 585 711
1500 13 19 33 53 82 115 165 230 313 356 420 487 593
1600 12 18 31 49 77 108 154 216 293 333 394 457 556 667
2000 14 25 40 62 86 123 173 235 267 315 365 444 533
2500 11 20 32 49 69 99 138 188 213 252 292 356 427
3000 16 26 41 58 82 115 156 178 210 244 296 356
3200 15 25 39 54 77 108 147 167 197 228 278 333
4000 12 20 31 43 62 86 117 133 157 183 222 267
5000 10 16 25 35 49 69 94 107 126 146 178 213
6300 13 20 27 39 55 74 85 100 116 141 169
8000 10 15 22 31 43 59 67 79 91 111 133
9600 13 18 26 36 49 56 66 76 93 111
10000 12 17 25 35 47 53 63 73 89 107
12000 10 14 21 29 39 44 52 61 74 89
15000 12 16 23 31 36 42 49 59 71
20000 12 17 23 27 31 37 44 53
24000 10 14 20 22 26 30 37 44
30000 12 16 20 25 30 40 49

ABB SACE - Electrical devices 75

 2.4 Protection against short-circuit

2 Protection of feeders
Correction factor for voltage other than 400 V: kv
Multiply the length value obtained from the table by the correction factor kv:

Ur [V] kv
(three-phase value)
2301 0.58
400 1
440 1.1
500 1.25
690 1.73
1
230 V single-phase is the equivalent of a three-phase 400 V system with distributed
neutral and with the cross section of the phase conductor the same as the cross section
area of the neutral conductor, so that kv is 0.58.

Correction factor for distributed neutral: kd

Multiply the length value obtained from the table by the correction factor kd:

2 . 1
kd =
3 1+ S
where SN
S is the phase cross section [mm2];
SN is the neutral cross section [mm2].

In particular:

if S = SN kd is 0.58;
if S = 2.S N kd is 0.39.

Correction factor for aluminium conductors: kr

If the cable is in aluminium, multiply the length value obtained from the table
above by the correction factor kr = 0.67.

76 ABB SACE - Electrical devices

 2.4 Protection against short-circuit

2 Protection of feeders
To summarize:
On the table, for the cross section and magnetic trip threshold it is possible to
read a maximum protected value L0. This length shall then be multiplied, if
necessary, by the correction factors in order to obtain a value that is compatible
with the installation operating conditions:

L = L 0 k v kd k r
Example 1
Neutral not distributed
Rated voltage = 400 V
Protective device: T2N160 TMD In100
Magnetic threshold: I3 = 1000 A
Phase cross section = Neutral cross section = 70 mm2
The table shows that at I3 = 1000 A, the 70 mm2 cable is protected up to 346 m.

Example 2
Neutral distributed
Rated voltage = 400 V
Protective device: T3S250 In200
Magnetic threshold: I3 = 2000 A
Phase cross section = 300 mm2
Neutral cross section = 150 mm2
For I3 = 2000 A and S = 300 mm2, a protected length equivalent of L0= 533 m
is obtained.

By applying the correction factor kd required when the neutral is distributed:

2 . 1 2 . 1
kd = = = 0.39
3 1+ S 3 1+ 300
SN 150

L= L0 . 0.39 = 533 . 0.39 = 207.9 m

This is the maximum protected length with neutral distributed.

ABB SACE - Electrical devices 77

 2 Protection of feeders

2.5 Neutral and protective conductors

Neutral conductor
The neutral conductor is a conductor that is connected to the system neutral
point (which generally but not necessarily coincides with the star centre of the
secondary windings of the transformer or the windings of the generator); it is
able to contribute to the transmission of electric power, thereby making available
a voltage that is different from the phase to phase voltage. In certain cases and
under specific conditions, the functions of neutral conductor and protective
conductor can be combined in a single conductor (PEN).

Protection and disconnection of the neutral conductor

If fault conditions arise, a voltage to earth may occur on the neutral conductor.
This may be caused by a phase to neutral short-circuit and by the disconnection
of the neutral conductor due to accidental breaking or to tripping of single-pole
devices (fuses or single-pole circuit breakers).
If the neutral conductor only is disconnected in a four-conductor circuit the
supply voltage to the single-phase loads may be altered so that they are supplied
by a voltage different from the U0 phase to neutral voltage (as shown in Fig. 1).
Therefore, all the necessary measures to prevent this type of fault shall be taken,
e.g. by not protecting the neutral conductor with single-pole devices.

P
P 3 . U0 . R 1
U1 =
P R1+ R2 1SDC010013F0001
N

U1 R1 R2

Figure 1: Disconnection of the neutral conductor

Moreover, in TN-C systems, voltage to earth arising on the neutral conductor
constitutes a hazard for people; in fact, since this conductor is also a protective
conductor, this voltage reaches the connected exposed conductive parts. For
TN-C systems, the Standards specify minimum cross sections (see next clause)
for the neutral conductor in order to prevent accidental breaking and they forbid
the use of any device (single-pole or multi-pole) that could disconnect the PEN.
The need for protection on the neutral conductor and the possibility of
disconnecting the circuit depend on the distribution system:

78 ABB SACE - Electrical devices

 2.5 Neutral and protective conductors

2 Protection of feeders
TT or TN systems:
if the cross section of the neutral conductor is the same or larger than the
cross section of the phase conductor, there is neither the need to detect
overcurrents on the neutral conductor nor to use a breaking device (neutral
conductor is not protected or disconnected); this requirement applies only if
there are no harmonics that may, at any instant, cause r.m.s. current values
on the neutral conductor higher than the maximum current detected on the
phase conductors;
if the cross section of the neutral conductor is less than the cross section of
the phase conductor, overcurrents on the neutral conductor must be detected
so as to have the phase conductors, but not necessarily the neutral conductor,
disconnected (neutral conductor protected but not disconnected): in this case
the overcurrents on the neutral conductor do not need to be detected if the
following conditions are simultaneously fulfilled:
1.the neutral conductor is protected against short-circuit by
the protective device of the phase conductors;
2.the maximum current that can flow through the neutral
conductor during normal service is lower than the neutral
current carrying capacity.
In TN-S systems, the neutral need not be disconnected if the supply conditions
are such that the neutral conductor can be considered to be reliable at earth potential.
As already mentioned, in TN-C systems, the neutral conductor is also a
protective conductor and cannot therefore be disconnected. Furthermore, if
the neutral conductor is disconnected, the exposed conductive parts of the
single-phase equipment could take the system rated voltage to earth.
In certain specific cases, the neutral conductor has to be disconnected to
prevent currents circulating between parallel supply sources (see Figures 2 and 3)

Figure 2: Three-phase alternative power supply with a 4-pole switch

Power supply 1 Power supply 2

NOTE - This method

prevents electromagnetic
fields due to stray currents L1 L1
in the main supply system L2 L2
of an installation. The sum L3 L3
PEN
of the currents within one Supplier
PE
cable must be zero. This
ensures that the neutral
current will flow only in the
neutral conductor of the
respective switched on User
circuit. The 3rd harmonic
1SDC010012F0201

(150 Hz) current of the line

conductors will be added
with the same phase angle
to the neutral conductor
current.
Current using equipment

ABB SACE - Electrical devices 79

 2.5 Neutral and protective conductors

2 Protection of feeders
Figure 3: Three-phase alternative power supply with non-suitable
3-pole switch

L1 L1
L2 L2
L3 L3
PEN
PE

NOTE A three-phase
alternative power supply

1SDC010014F0001
with a non-suitable 3-pole
switch, due to
unintentional circular stray
currents generating
electromagnetic fields.

IT system:
The Standard advises against distributing the neutral conductor in IT systems.
If the neutral conductor is distributed, the overcurrents must be detected on
the neutral conductor of each circuit in order to disconnect all the live conductors
on the corresponding circuit, including the neutral one (neutral conductor
protected and disconnected).
Overcurrents do not need to be detected on the neutral conductor in any of the
following cases:
the neutral conductor is protected against short-circuit by a protective device
fitted upstream;
the circuit is protected by a residual current device with rated residual current
lower than 0.15 times the current carrying capacity of the corresponding neutral
conductor. This device must disconnect all the live conductors, the neutral
conductor included.

For all distribution systems, whenever necessary, connection and disconnection

of the neutral conductor, shall ensure that:
the neutral conductor is not disconnected before the phase conductor;
the neutral conductor is connected at the same moment or before the phase
conductor.

80 ABB SACE - Electrical devices

 2.5 Neutral and protective conductors

2 Protection of feeders

START

Upstream protection TT/TN System? SN S?

no for the neutral? no yes yes
no
yes

Is the circuit protected

by a RCD with Is the neutral protected by
In 0.15 x Neutral the short-circuit protection
no carrying capacity ? no
of the phase conductor?

yes yes

Neutral max current

<
Neutral carrying capacity (Iz)? no

yes

1SDC010013F0201

It is necessary to: It is necessary to: It is necessary to: It is necessary to: It is not necessary:
detect the neutral current - open all the contacts -open the phase contacts -detect the neutral current; -the presence of a
in order to open all the contacts (phase and neutral) It is not necessary to: -open the phase contacts; breaking device
(phase and neutral). It is not necessary to: -detect the neutral overcurrent; It is not necessary to: for the neutral.
-detect the neutral current. -open the neutral contact. -open the neutral contact.

Neutral shall not be disconnected before the phase conductors

Neutral shall be reconnected at the same time as
or before the phase conductors

ABB SACE - Electrical devices 81

 2.5 Neutral and protective conductors

2 Protection of feeders
Determination of the minimum cross section of the neutral conductor
The neutral conductor, if any, shall have the same cross section as the line
conductor:
in single-phase, two-wire circuits whatever the section;
in polyphase and single-phase three-wire circuits, when the size of the line
conductors is less than or equal to 16 mm2 in copper, or 25 mm2 in
aluminium.1
The cross section of the neutral conductor can be less than the cross section
of the phase conductor when the cross section of the phase conductor is
greater than 16 mm2 with a copper cable, or 25 mm2 with an aluminium cable,
if both the following conditions are met:
the cross section of the neutral conductor is at least 16 mm2 for copper
conductors and 25 mm2 for aluminium conductors;
there is no high harmonic distortion of the load current. If there is high harmonic
distortion (the harmonic content is greater than 10%), as for example in
equipment with discharge lamps, the cross section of the neutral conductor
cannot be less than the cross section of the phase conductors.

Table 1: Minimum cross sections of the neutral conductor

Phase cross section Min. neutral cross section
S [mm2] SN [mm2]
Single-phase/two-phase circuits
Cu/Al Any S*
Three-phase circuits S 16 S*
Cu S > 16 16
Three-phase circuits S 25 S*
Al S > 25 25
*
for TN-C systems, the Standards specify a minimum cross section of 10 mm2 for
copper and 16 mm2 for aluminium conductors

1
The cross section of phase conductors shall be dimensioned in compliance with the
instructions of the Chapter 2.2.1 Current carrying capacity and methods of installation

82 ABB SACE - Electrical devices

 2.5 Neutral and protective conductors

2 Protection of feeders
Protective conductor
Determination of the minimum cross sections
The minimum cross section of the protective conductor can be determined by
using the following table:

Table 2: Cross section of the protective conductor

Cross section of Minimum cross section of the corresponding

line conductor S protective conductor
[mm2 ] [mm2 ]

If the protective conductor is of the If the protective conductor is not of the same
same material as the line conductor material as the line conductor

k1 .
S 16 S S
k
2

k1 .
16 < S 25 16* 16
k
2

S* k1 . S
S > 25
2 k2 2

Where
k1 is the value of k for the line conductor, selected from Table 1 Chapter 2.4 according to the materials of

1SDC010014F0201
the conductor and insulation;
k2 is the value of k for the protective conductor.
* For a PEN conductor, the reduction of the cross section is permitted only in accordance with the rules for sizing of the neutral conductor.

For a more accurate calculation and if the protective conductor is subjected to

adiabatic heating from an initial known temperature to a final specified tempe-
rature (applicable for fault extinction time no longer than 5s), the minimum cross
section of the protective conductor SPE can be obtained by using the following
formula:

I 2t
SPE = (1)
k
where:
SPE is the cross section of the protective conductor [mm2];
I is the r.m.s. current flowing through the protective conductor in the event of
a fault with low impedance [A];
t is the trip time of the protective device [s];

ABB SACE - Electrical devices 83

 2.5 Neutral and protective conductors

2 Protection of feeders
k is a constant which depends on the material of the protective conductor, on
the type of insulation and on initial and final temperature. The most common
values can be taken from Tables 3 and 4.

Table 3: Values of k for insulated protective conductors not

incorporated in cables and not bunched with other cables

Temperature Material of conductor

Conductor insulation C b Copper Aluminium Steel
Initial Final Values for k
70 C PVC 30 160/140 a 143/133 a 95/88 a 52/49 a
a a a
90 C PVC 30 143/133 143/133 95/88 52/49 a
90 C thermosetting 30 250 176 116 64
60 C rubber 30 200 159 105 58
85 C rubber 30 220 168 110 60

1SDC010015F0201
Silicon rubber 30 350 201 133 73

a
The lower value applies to PVC insulated conductors of cross section greater than 300 mm2.
b
Temperature limits for various types of insulation are given in IEC 60724.

Table 4: Values of k for protective conductors as a core incorporated

in a cable or bunched with other cables or insulated conductors

Temperature Material of conductor

Conductor insulation C b Copper Aluminium Steel
Initial Final Values for k
70 C PVC 70 160/140 a 115/103 a 76/68 a 42/37 a
90 C PVC 90 160/140 a 100/86 a 66/57 a 36/31 a
90 C thermosetting 90 250 143 94 52
60 C rubber 60 200 141 93 51
85 C rubber 85 220 134 89 48
1SDC010015F0201

Silicon rubber 180 350 132 87 47

a
The lower value applies to PVC insulated conductors of cross section greater than 300 mm2.
b
Temperature limits for various types of insulation are given in IEC 60724.

84 ABB SACE - Electrical devices

 2.5 Neutral and protective conductors

2 Protection of feeders
Further values of k can be taken from the Tables in Annex D, which provides
the formula for accurate calculation of the value of k.

If Table 2 or formula (1) do not provide a standardized cross section, a larger

standardized cross section shall be chosen.

Regardless of whether Table 2 or formula (1) are used, the cross section of the
protective conductor, which is not part of the supply cable, shall be at least:
- 2.5 mm2 Cu/16 mm2 Al, if a mechanical protection is provided;
- 4 mm2 Cu/16 mm2 Al, if no mechanical protection ise provided.

For current using equipment intended for permanent connection and with a
protective conductor current exceeding 10 mA, reinforced protective conductors
shall be designed as follows:
either the protective conductor shall have a cross-sectional area of at least 10
mm2 Cu or 16 mm2 Al, through its total run;
or a second protective conductor of at least the same cross-sectional area as
required for protection against indirect contact shall be laid up to a point
where the protective conductor has a cross-sectional area not less than 10
mm2 Cu or 16 mm2 Al. This requires that the appliance has a separate terminal
for a second protective conductor;

When overcurrent protective devices are used for protection against electric
shock, the protective conductor shall be incorporated in the same wiring system
as the live conductors or be located in their immediate proximity.

ABB SACE - Electrical devices 85

 2 Protection of feeders

2.6 Busbar trunking systems (BTSs)

In electrical installations for industrial environments, busbar trunking systems

(BTSs) optimize the power distribution despite the inevitable modifications that
are carried out (additions, displacements, replacement of loads) and to facilita-
te maintenance work and safety verifications.
They are mainly used for:
- supplying sources of light, safety and low power distribution;
- lighting lines (medium power);
- power supply and distribution (medium and large power);
- supplying moving equipment (bridge cranes).

Busbar trunking systems are subject to the following Standards:

- IEC 60439 1 Low-voltage switchgear and controlgear assemblies Part 1:
Type-tested and partially type-tested assemblies
- IEC 60439 2 Low-voltage switchgear and controlgear assemblies Part 2:
Particular requirements for busbar trunking systems (busways).

BTSs consist of:

- conductors/busbars;
- coupling: electrical and mechanical connecting elements for different elements;
- straight elements: base elements of the line for carrying energy from the source
to the loads;
- routing elements: flexible joints for the creation of curves or overcoming
obstacles, horizontal and vertical angles, tee joints and cross elements to
create any type of route;
- pull boxes: elements that enable lamps or operating machines to be supplied
directly with integrated protection (fuses or circuit breakers);
- suspensions/accessories: hanging and fixing elements for BTS and for any
support required for special loads (lighting components, etc).

Dimensioning of a BTS
To dimension a BTS, the load current must be determined using the following
data:

Power supply
General type of load supply:
- single-phase
- three-phase.
Type of BTS supply:
- from one end;
- from both ends;
- central power supply.
Rated voltage
Short-circuit current at the supply point
Ambient temperature.

Loads

Number, distribution, power and cos and type of loads supplied by the same
BTS

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BTS geometry

Type of installation:
- flat;
- edge-on;
- vertical.
Length.

NOTE: BTSs shall be placed at a distance from the walls and the ceilings in such a way as
to enable visual inspection of connections during assembly and to facilitate insertion of the
branch units.
If possible, it is preferable to install the BTS edge-on so as to improve mechanical resistance
and reduce any possible deposit of powder and polluting substances that might affect the
level of internal insulation.

Load current calculation for three-phase system

Load current Ib for a three-phase system is calculated by the following formula:

Pt . b
Ib = [A] (1)
3 U . cos
.
r m
where:
Pt is the sum of the active power of all the installed loads [W];
b is the supply factor, which is:
- 1 if the BTS is supplied from one side only;
- 1/2 if the BTS is supplied from the centre or from both ends
simultaneously;
Ur is the operating voltage [V];
cosm is the average power factor of the loads.

Choice of BTS current carrying capacity

A BTS shall be chosen so that its current carrying capacity Iz complies with the
following formula:

I b I Z 0 . kt = I Z (2)

where:
IZ0 is the current that the BTS can carry for an indefinite time at the reference
temperature (40 C);
Ib is the load current;
kt is the correction factor for ambient temperature values other than the
reference ambient temperature shown on Table 1.

Table 1: Correction factor kt for ambient temperature other than 40 C

Ambient
Temperature [C] 15 20 25 30 35 40 45 50
kt 1.2 1.17 1.12 1.08 1.05 1 0.95 0.85

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Note: the following tables refer to Zucchini S.p.A. products

Table 2: Current carrying capacity IZ0 of copper BTS

Number of IZ0 rph* xph Ur
Size Type conductors [A] [m/m] [m/m] [V]
25 LB254 25A 4 cond. Cu 4 25 6.964 1.144 400
25 HL254 25A 4 cond. Cu 4 25 6.876 1.400 400
25 HL2544 25A 4+4 cond. Cu 4+4 25 6.876 1.400 400
40 LB404 40A 4 cond. Cu 4 40 3.556 0.792 400
40 HL404 40A 4 cond. Cu 4 40 3.516 1.580 400
40 HL4044 40A 4+4 cond. Cu 4+4 40 3.516 1.580 400
40 SL 40A 4 cond. Cu 4 40 2.173 0.290 400
63 SL 63A 4 cond. Cu 4 63 1.648 0.637 400
100 MS 100A 4 cond. Cu 4 100 0.790 0.366 400
160 MS 160A 4 cond. Cu 4 160 0.574 0.247 400
160 SB4 160A 4 cond. Cu 4 160 0.335 0.314 500
160 SB5 160A 5 cond. Cu 5 160 0.335 0.314 500
160 SB6 160A 5 cond. Cu 5 160 0.335 0.314 500
160 SB7 160A 4 cond. Cu 4 160 0.335 0.314 500
250 MR 250A 4 cond. Cu 4 250 0.285 0.205 1000
250 MRf 250A 5 cond. Cu 5 250 0.285 0.205 1000
250 SB4 250A 4 cond. Cu 4 250 0.194 0.205 500
250 SB5 250A 5 cond. Cu 5 250 0.194 0.205 500
250 SB6 250A 5 cond. Cu 5 250 0.194 0.205 500
250 SB7 250A 4 cond. Cu 4 250 0.194 0.205 500
315 MR 315A 4 cond. Cu 4 315 0.216 0.188 1000
315 MRf 315A 5 cond. Cu 5 315 0.216 0.188 1000
350 SB4 350A 4 cond. Cu 4 350 0.142 0.188 500
350 SB5 350A 5 cond. Cu 5 350 0.142 0.188 500
350 SB6 350A 5 cond. Cu 5 350 0.142 0.188 500
350 SB7 350A 4 cond. Cu 4 350 0.142 0.188 500
400 MR 400A 4 cond. Cu 4 400 0.115 0.129 1000
400 MRf 400A 5 cond. Cu 5 400 0.115 0.129 1000
500 SB4 500A 4 cond. Cu 4 500 0.092 0.129 500
500 SB5 500A 5 cond. Cu 5 500 0.092 0.129 500
500 SB6 500A 5 cond. Cu 5 500 0.092 0.129 500
500 SB7 500A 4 cond. Cu 4 500 0.092 0.129 500
630 MR 630A 4 cond. Cu 4 630 0.073 0.122 1000
630 MRf 630A 5 cond. Cu 5 630 0.073 0.122 1000
700 SB4 700A 4 cond. Cu 4 700 0.077 0.122 500
700 SB5 700A 5 cond. Cu 5 700 0.077 0.122 500

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Number of IZ0 rph* xph Ur

Size Type conductors [A] [m/m] [m/m] [V]
700 SB6 700A 5 cond. Cu 5 700 0.077 0.122 500
700 SB7 700A 4 cond. Cu 4 700 0.077 0.122 500
800 MR 800A 4 cond. Cu 4 800 0.047 0.122 1000
800 MRf 800A 5 cond. Cu 5 800 0.047 0.122 1000
800 SC 800A 4 cond. Cu 4 800 0.038 0.027 1000
800 SB4 800A 4 cond. Cu 4 800 0.072 0.122 500
800 SB5 800A 5 cond. Cu 5 800 0.072 0.122 500
800 SB6 800A 5 cond. Cu 5 800 0.072 0.122 500
800 SB7 800A 4 cond. Cu 4 800 0.072 0.122 500
1000 MR 1000A 4 cond. Cu 4 1000 0.038 0.120 1000
1000 MRf 1000A 5 cond. Cu 5 1000 0.038 0.120 1000
1000 SC 1000A 4 cond. Cu 4 1000 0.037 0.026 1000
1000 HRC1 1000A 4 cond. Cu 4 1000 0.038 0.097 1000
1000 SB4 1000A 4 cond. Cu 4 1000 0.068 0.120 500
1000 SB5 1000A 5 cond. Cu 5 1000 0.068 0.120 500
1000 SB6 1000A 5 cond. Cu 5 1000 0.068 0.120 500
1000 SB7 1000A 4 cond. Cu 4 1000 0.068 0.120 500
1200 SC 1200A 4 cond. Cu 4 1200 0.035 0.021 1000
1250 SC 1250A 4 cond. Cu 4 1250 0.034 0.023 1000
1250 HRC1 1250A 4 cond. Cu 4 1250 0.035 0.076 1000
1500 SC 1500A 4 cond. Cu 4 1500 0.030 0.022 1000
1600 SC 1600A 4 cond. Cu 4 1600 0.025 0.018 1000
1600 HRC1 1600A 4 cond. Cu 4 1600 0.034 0.074 1000
2000 SC 2000A 4 cond. Cu 4 2000 0.020 0.015 1000
2000 HRC1 2000A 4 cond. Cu 4 2000 0.025 0.074 1000
2400 SC 2400A 4 cond. Cu 4 2400 0.019 0.012 1000
2500 SC 2500A 4 cond. Cu 4 2500 0.016 0.011 1000
2500 HRC1 2500A 4 cond. Cu 4 2500 0.019 0.040 1000
3000 SC 3000A 4 cond. Cu 4 3000 0.014 0.011 1000
3000 HRC2 3000A 4 cond. Cu 4 3000 0.017 0.031 1000
3200 SC 3200A 4 cond. Cu 4 3200 0.013 0.009 1000
3200 HRC2 3200A 4 cond. Cu 4 3200 0.015 0.031 1000
4000 SC 4000A 4 cond. Cu 4 4000 0.011 0.007 1000
4000 HRC2 4000A 4 cond. Cu 4 4000 0.011 0.026 1000
5000 SC 5000A 4 cond. Cu 4 5000 0.008 0.005 1000
5000 HRC2 5000A 4 cond. Cu 4 5000 0.008 0.023 1000
*phase resistance at Iz0

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Table 3: Current carrying capacity IZ0 of aluminium BTS

Number of IZ0 rph* xph Ur

Size Type conductors [A] [m/m] [m/m] [V]
160 MR 160A 4 cond. Al 4 160 0.591 0.260 1000
160 MRf 160A 5 cond. Al 5 160 0.591 0.260 1000
160 SB4 160A 4 cond. Al 4 160 0.431 0.260 500
160 SB5 160A 5 cond. Al 5 160 0.431 0.260 500
160 SB6 160A 5 cond. Al 5 160 0.431 0.260 500
160 SB7 160A 4 cond. Al 4 160 0.431 0.260 500
250 MR 250A 4 cond. Al 4 250 0.394 0.202 1000
250 MRf 250A 5 cond. Al 5 250 0.394 0.202 1000
250 SB4 250A 4 cond. Al 4 250 0.226 0.202 500
250 SB5 250A 5 cond. Al 5 250 0.226 0.202 500
250 SB6 250A 5 cond. Al 5 250 0.226 0.202 500
250 SB7 250A 4 cond. Al 4 250 0.226 0.202 500
315 MR 315A 4 cond. Al 4 315 0.236 0.186 1000
315 MRf 315A 5 cond. Al 5 315 0.236 0.186 1000
315 SB4 315A 4 cond. Al 4 315 0.181 0.186 500
315 SB5 315A 5 cond. Al 5 315 0.181 0.186 500
315 SB6 315A 5 cond. Al 5 315 0.181 0.186 500
315 SB7 315A 4 cond. Al 4 315 0.181 0.186 500
400 MR 400A 4 cond. Al 4 400 0.144 0.130 1000
400 MRf 400A 5 cond. Al 5 400 0.144 0.130 1000
400 SB4 400A 4 cond. Al 4 400 0.125 0.130 500
400 SB5 400A 5 cond. Al 5 400 0.125 0.130 500
400 SB6 400A 5 cond. Al 5 400 0.125 0.130 500
400 SB7 400A 4 cond. Al 4 400 0.125 0.130 500
500 SB4 500A 4 cond. Al 4 500 0.102 0.127 500
500 SB5 500A 5 cond. Al 5 500 0.102 0.127 500
500 SB6 500A 5 cond. Al 5 500 0.102 0.127 500
500 SB7 500A 4 cond. Al 4 500 0.102 0.127 500
630 MR 630A 4 cond. Al 4 630 0.072 0.097 1000
630 MRf 630A 5 cond. Al 5 630 0.072 0.097 1000
630 SC 630A 4 cond. Al 4 630 0.072 0.029 1000

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Number of IZ0 rph* xph Ur

Size Type conductors [A] [m/m] [m/m] [V]
630 SB4 630A 4 cond. Al 4 630 0.073 0.097 500
630 SB5 630A 5 cond. Al 5 630 0.073 0.097 500
630 SB6 630A 5 cond. Al 5 630 0.073 0.097 500
630 SB7 630A 4 cond. Al 4 630 0.073 0.097 500
800 MR 800A 4 cond. Al 4 800 0.062 0.096 1000
800 MRf 800A 5 cond. Al 5 800 0.062 0.096 1000
800 SC 800A 4 cond. Al 4 800 0.067 0.027 1000
800 SB4 800A 4 cond. Al 4 800 0.071 0.096 500
800 SB5 800A 5 cond. Al 5 800 0.071 0.096 500
800 SB6 800A 5 cond. Al 5 800 0.071 0.096 500
800 SB7 800A 4 cond. Al 4 800 0.071 0.096 500
1000 SC 1000A 4 cond. Al 4 1000 0.062 0.023 1000
1000 HRC1 1000A 4 cond. Al 4 1000 0.068 0.087 1000
1200 SC 1200A 4 cond. Al 4 1200 0.054 0.023 1000
1250 SC 1250A 4 cond. Al 4 1250 0.044 0.021 1000
1250 HRC1 1250A 4 cond. Al 4 1250 0.044 0.066 1000
1500 SC 1500A 4 cond. Al 4 1500 0.041 0.023 1000
1600 SC 1600A 4 cond. Al 4 1600 0.035 0.017 1000
1600 HRC1 1600A 4 cond. Al 4 1600 0.041 0.066 1000
2000 SC 2000A 4 cond. Al 4 2000 0.029 0.016 1000
2000 HRC1 2000A 4 cond. Al 4 2000 0.034 0.053 1000
2250 HRC2 2250A 4 cond. Al 4 2250 0.032 0.049 1000
2400 SC 2400A 4 cond. Al 4 2400 0.028 0.012 1000
2500 SC 2500A 4 cond. Al 4 2500 0.022 0.011 1000
2500 HRC2 2500A 4 cond. Al 4 2500 0.022 0.034 1000
3000 SC 3000A 4 cond. Al 4 3000 0.020 0.011 1000
3200 SC 3200A 4 cond. Al 4 3200 0.017 0.009 1000
3200 HRC2 3200A 4 cond. Al 4 3200 0.020 0.034 1000
4000 SC 4000A 4 cond. Al 4 4000 0.014 0.008 1000
4000 HRC2 4000A 4 cond. Al 4 4000 0.017 0.024 1000
4500 HRC2 4500A 4 cond. Al 4 4500 0.014 0.024 1000
*phase resistance at Iz0

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BTS protection
Protection against overload
BTSs are protected against overload by using the same criterion as that used
for the cables. The following formula shall be verified:

I b In I z (3)
where:
Ib is the current for which the circuit is designed;
In is the rated current of the protective device; for adjustable protective devices,
the rated current In is the set current;
Iz is the continuous current carrying capacity of the BTS.

Protection against short-circuit1

1 The protection against
short-circuit does not The BTS must be protected against thermal overload and electrodynamic effects
need to be checked if due to the short-circuit current.
MCBs up to 63 A are used
whenever correctly
dimensioned for overload
Protection against thermal overload
protection. In such cases, The following formula shall be fulfilled:
in fact, protection against
both thermal and I2t CB I2t BTS (4)
electrodynamic effects is
certainly adequate where:
because of the energy and I2tCB is the specific let-through energy of the circuit-breaker at the maximum
peak limitations offered by
these protective devices.
short-circuit current value at the installation point. This can be extrapolated
from the curves shown in Volume 1 Chapter 3.4;
I2tBTS is the withstood energy of the BTS and it is normally given by the
manufacturer (see Tables 4 and 5).

Protection against electrodynamic effects

The following formula shall be fulfilled:

Ikp CB Ikp BTS (5)

where:
Ikp CB is the peak limited by the circuit-breaker at the maximum short-circuit
current value at the installation point. This can be extrapolated from the
limitation curves shown in Volume 1, Chapter 3.3;
Ikp BTS is the maximum peak current value of the BTS (see Tables 4 and 5).

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START

Ib

yes
Temperature
<> 40 C ?

no

kt from
kt=1 Table 1

BTS choice
(I b < kt*IZ0 =IZ )

Voltage drop no
OK ?

yes

Circuit-breaker
choice

no
Ib < InCB < IZ ?

yes

no
1SDC010017F0201

I2 t CB < I2 t BTS ?

yes

no
IkpCB < I kp BTS ?

yes

END

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Table 4: Values of the withstood energy and peak current of copper BTS

Size Type I2tph I2tN I2tPE Ipeakph IpeakN

[(kA)2s] [(kA)2s] [(kA)2s] [kA] [kA]
25 LB254 25A 4 cond. Cu 0.48 0.48 0.48 10 10
25 HL254 25A 4 cond. Cu 0.64 0.64 0.64 10 10
25 HL2544 25A 4+4 cond. Cu 0.64 0.64 0.64 10 10
40 LB404 40A 4 cond. Cu 0.73 0.73 0.73 10 10
40 HL404 40A 4 cond. Cu 1 1 1 10 10
40 HL4044 40A 4+4 cond. Cu 1 1 1 10 10
40 SL 40A 4 cond. Cu 7.29 7.29 7.29 10 10
63 SL 63A 4 cond. Cu 7.29 7.29 7.29 10 10
100 MS 100A 4 cond. Cu 20.25 20.25 20.25 10 10
160 MS 160A 4 cond. Cu 30.25 30.25 30.25 10 10
160 SB4 160A 4 cond. Cu 100 60 60 17 10.2
160 SB5 160A 5 cond. Cu 100 100 100 17 10.2
160 SB6 160A 5 cond. Cu 100 100 100 17 10.2
160 SB7 160A 4 cond. Cu 100 100 100 17 10.2
250 MR 250A 4 cond. Cu 312.5 187.5 187.5 52.5 31.5
250 MRf 250A 5 cond. Cu 312.5 312.5 312.5 52.5 31.5
250 SB4 250A 4 cond. Cu 169 101.4 101.4 26 15.6
250 SB5 250A 5 cond. Cu 169 169 169 26 15.6
250 SB6 250A 5 cond. Cu 169 169 169 26 15.6
250 SB7 250A 4 cond. Cu 169 169 169 26 15.6
315 MR 315A 4 cond. Cu 312.5 187.5 187.5 52.5 31.5
315 MRf 315A 5 cond. Cu 312.5 312.5 312.5 52.5 31.5
350 SB4 350A 4 cond. Cu 169 101.4 101.4 26 15.6
350 SB5 350A 5 cond. Cu 169 169 169 26 15.6
350 SB6 350A 5 cond. Cu 169 169 169 26 15.6
350 SB7 350A 4 cond. Cu 169 169 169 26 15.6
400 MR 400A 4 cond. Cu 900 540 540 63 37.8
400 MRf 400A 5 cond. Cu 900 900 900 63 37.8
500 SB4 500A 4 cond. Cu 756.25 453.75 453.75 58 34.8
500 SB5 500A 5 cond. Cu 756.25 756.25 756.25 58 34.8
500 SB6 500A 5 cond. Cu 756.25 756.25 756.25 58 34.8
500 SB7 500A 4 cond. Cu 756.25 756.25 756.25 58 34.8
630 MR 630A 4 cond. Cu 1296 777.6 777.6 75.6 45.4
630 MRf 630A 5 cond. Cu 1296 1296 1296 75.6 45.4
700 SB4 700A 4 cond. Cu 756.25 453.75 453.75 58 34.8
700 SB5 700A 5 cond. Cu 756.25 756.25 756.25 58 34.8

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Size Type I2tph I2tN I2tPE Ipeakph IpeakN

[(kA)2s] [(kA)2s] [(kA)2s] [kA] [kA]
700 SB6 700A 5 cond. Cu 756.25 756.25 756.25 58 34.8
700 SB7 700A 4 cond. Cu 756.25 756.25 756.25 58 34.8
800 MR 800A 4 cond. Cu 1296 777.6 777.6 75.6 45.4
800 MRf 800A 5 cond. Cu 1296 1296 1296 75.6 45.4
800 SC 800A 4 cond. Cu 3969 3969 2381.4 139 83.4
800 SB4 800A 4 cond. Cu 756.25 453.75 453.75 58 34.8
800 SB5 800A 5 cond. Cu 756.25 756.25 756.25 58 34.8
800 SB6 800A 5 cond. Cu 756.25 756.25 756.25 58 34.8
800 SB7 800A 4 cond. Cu 756.25 756.25 756.25 58 34.8
1000 MR 1000A 4 cond. Cu 1296 777.6 777.6 75.6 45.4
1000 MRf 1000A 5 cond. Cu 1296 1296 1296 75.6 45.4
1000 SC 1000A 4 cond. Cu 3969 3969 2381.4 139 83.4
1000 HRC1 1000A 4 cond. Cu 1600 1600 960 84 50.4
1000 SB4 1000A 4 cond. Cu 1024 614.4 614.4 60 36
1000 SB5 1000A 5 cond. Cu 1024 1024 1024 60 36
1000 SB6 1000A 5 cond. Cu 1024 1024 1024 60 36
1000 SB7 1000A 4 cond. Cu 1024 1024 1024 60 36
1200 SC 1200A 4 cond. Cu 7744 7744 4646.4 194 116.4
1250 SC 1250A 4 cond. Cu 7744 7744 4646.4 194 116.4
1250 HRC1 1250A 4 cond. Cu 2500 2500 1500 105 63
1500 SC 1500A 4 cond. Cu 7744 7744 4646.4 194 116.4
1600 SC 1600A 4 cond. Cu 7744 7744 4646.4 194 116.4
1600 HRC1 1600A 4 cond. Cu 2500 2500 1500 105 63
2000 SC 2000A 4 cond. Cu 7744 7744 4646.4 194 116.4
2000 HRC1 2000A 4 cond. Cu 3600 3600 2160 132 79.2
2400 SC 2400A 4 cond. Cu 7744 7744 4646.4 194 116.4
2500 SC 2500A 4 cond. Cu 7744 7744 4646.4 194 116.4
2500 HRC1 2500A 4 cond. Cu 4900 4900 2940 154 92.4
3000 SC 3000A 4 cond. Cu 30976 30976 18585.6 387 232.2
3000 HRC2 3000A 4 cond. Cu 8100 8100 4860 198 118.8
3200 SC 3200A 4 cond. Cu 30976 30976 18585.6 387 232.2
3200 HRC2 3200A 4 cond. Cu 8100 8100 4860 198 118.8
4000 SC 4000A 4 cond. Cu 30976 30976 18585.6 387 232.2
4000 HRC2 4000A 4 cond. Cu 8100 8100 4860 198 118.8
5000 SC 5000A 4 cond. Cu 30976 30976 18585.6 387 232.2
5000 HRC2 5000A 4 cond. Cu 10000 10000 6000 220 132

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Table 5: Values of the withstood energy and peak current of
aluminium BTS
Size Type I2tph I2tN I2tPE Ipeakph IpeakN
[(kA)2s] [(kA)2s] [(kA)2s] [kA] [kA]
160 MR 160A 4 cond. Al 112.5 67.5 67.5 30 18
160 MRf 160A 5 cond. Al 112.5 112.5 112.5 30 18
160 SB4 160A 4 cond. Al 100 60 60 17 10.2
160 SB5 160A 5 cond. Al 100 100 100 17 10.2
160 SB6 160A 5 cond. Al 100 100 100 17 10.2
160 SB7 160A 4 cond. Al 100 100 100 17 10.2
250 MR 250A 4 cond. Al 312.5 187.5 187.5 52.5 31.5
250 MRf 250A 5 cond. Al 312.5 312.5 312.5 52.5 31.5
250 SB4 250A 4 cond. Al 169 101.4 101.4 26 15.6
250 SB5 250A 5 cond. Al 169 169 169 26 15.6
250 SB6 250A 5 cond. Al 169 169 169 26 15.6
250 SB7 250A 4 cond. Al 169 169 169 26 15.6
315 MR 315A 4 cond. Al 625 375 375 52.5 31.5
315 MRf 315A 5 cond. Al 625 625 625 52.5 31.5
315 SB4 315A 4 cond. Al 169 101.4 101.4 26 15.6
315 SB5 315A 5 cond. Al 169 169 169 26 15.6
315 SB6 315A 5 cond. Al 169 169 169 26 15.6
315 SB7 315A 4 cond. Al 169 169 169 26 15.6
400 MR 400A 4 cond. Al 900 540 540 63 37.8
400 MRf 400A 5 cond. Al 900 900 900 63 37.8
400 SB4 400A 4 cond. Al 625 375 375 52.5 31.5
400 SB5 400A 5 cond. Al 625 625 625 52.5 31.5
400 SB6 400A 5 cond. Al 625 625 625 52.5 31.5
400 SB7 400A 4 cond. Al 625 625 625 52.5 31.5
500 SB4 500A 4 cond. Al 625 375 375 52.5 31.5
500 SB5 500A 5 cond. Al 625 625 625 52.5 31.5
500 SB6 500A 5 cond. Al 625 625 625 52.5 31.5
500 SB7 500A 4 cond. Al 625 625 625 52.5 31.5
630 MR 630A 4 cond. Al 1296 777.6 777.6 75.6 45.4
630 MRf 630A 5 cond. Al 1296 1296 1296 75.6 45.4
630 SC 630A 4 cond. Al 1444 1444 866.4 80 48

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Size Type I2tph I2tN I2tPE Ipeakph IpeakN

[(kA)2s] [(kA)2s] [(kA)2s] [kA] [kA]
630 SB4 630A 4 cond. Al 1024 614.4 614.4 67.5 40.5
630 SB5 630A 5 cond. Al 1024 1024 1024 67.5 40.5
630 SB6 630A 5 cond. Al 1024 1024 1024 67.5 40.5
630 SB7 630A 4 cond. Al 1024 1024 1024 67.5 40.5
800 MR 800A 4 cond. Al 1296 777.6 777.6 75.6 45.4
800 MRf 800A 5 cond. Al 1296 1296 1296 75.6 45.4
800 SC 800A 4 cond. Al 1764 1764 1058.4 88 52.8
800 SB4 800A 4 cond. Al 1024 614.4 614.4 67.5 40.5
800 SB5 800A 5 cond. Al 1024 1024 1024 67.5 40.5
800 SB6 800A 5 cond. Al 1024 1024 1024 67.5 40.5
800 SB7 800A 4 cond. Al 1024 1024 1024 67.5 40.5
1000 SC 1000A 4 cond. Al 6400 6400 3840 176 105.6
1000 HRC1 1000A 4 cond. Al 1600 1600 960 84 50.4
1200 SC 1200A 4 cond. Al 6400 6400 3840 176 105.6
1250 SC 1250A 4 cond. Al 6400 6400 3840 176 105.6
1250 HRC1 1250A 4 cond. Al 2500 2500 1500 105 63
1500 SC 1500A 4 cond. Al 6400 6400 3840 176 105.6
1600 SC 1600A 4 cond. Al 6400 6400 3840 176 105.6
1600 HRC1 1600A 4 cond. Al 2500 2500 1500 105 63
2000 SC 2000A 4 cond. Al 6400 6400 3840 176 105.6
2000 HRC1 2000A 4 cond. Al 3600 3600 2160 132 79.2
2250 HRC2 2250A 4 cond. Al 4900 4900 2940 154 92.4
2400 SC 2400A 4 cond. Al 25600 25600 15360 352 211.2
2500 SC 2500A 4 cond. Al 25600 25600 15360 352 211.2
2500 HRC2 2500A 4 cond. Al 8100 8100 4860 198 118.8
3000 SC 3000A 4 cond. Al 25600 25600 15360 352 211.2
3200 SC 3200A 4 cond. Al 25600 25600 15360 352 211.2
3200 HRC2 3200A 4 cond. Al 8100 8100 4860 198 118.8
4000 SC 4000A 4 cond. Al 25600 25600 15360 352 211.2
4000 HRC2 4000A 4 cond. Al 8100 8100 4860 198 118.8
4500 HRC2 4500A 4 cond. Al 10000 10000 6000 220 132

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Protection of the outgoing feeders
If the outgoing feeder, which generally consists of cable duct, is not already
protected against short-circuit and overload by the device located upstream of
the cable, the following measures shall be taken:

- protection against short-circuit:

there is no need to protect the feeder against the short-circuit if simultaneously:
a. the length does not exceed 3 metres;
b. the risk of short-circuit is minimized;
c. there is no inflammable material nearby.

In explosive environments and environments with greater risk of fire, protection

against short-circuit is always required;

- protection against overload:

the current carrying capacity of the feeder is generally lower than that of the
BTS. It is therefore necessary to protect also the feeder against overload.
The protection device against overload can be placed inside the pull box or on
the incoming panel.
In the latter case, protection against overload can also be provided by the
circuit breakers protecting the single outgoing feeder from the panel only if the
sum of their rated currents is lower or equal to the current carrying capacity Iz
of the outgoing feeder.
In locations with greater risk of fire, the overload protection device shall be
installed at the outgoing point, i.e. inside the pull box.

Voltage drop
If a BTS is particularly long, the value of the voltage drop must be verified.
For three-phase systems with a power factor (cosm) not lower than 0.8, the
voltage drop can be calculated by using the following simplified formula:

a . 3 . Ib . L. ( rt . cos m + x . sin m )
u= [V] (6a)
1000

For single-phase BTS the formula is:

a . 2 . Ib . L. ( rt . cos m + x . sin m )
u= [V] (6b)
1000

where:
a is the current distribution factor, which depends on the circuit supply and
the arrangement of the electric loads along the BTS, as shown in Table 6:

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Table 6: Current distribution factor
Type of Arrangement Current distribution
supply of loads factor
From one end only Load concentrated at the end 1
Evenly distributed load 0.5
From both ends Evenly distributed load 0.25
Central Load concentrated at the ends 0.25
Evenly distributed load 0.125

Ib is the load current [A];

L is the BTS length [m];
rt is the phase resistance per unit of length of BTS, measured under thermal
steady-state conditions [m/m];
x is the phase reactance per unit of length of BTS [m/m];
cosm is average power factor of the loads.

Percentage voltage drop is obtained from:

u .
u% = 100 (7)
Ur
where Ur is rated voltage.

To reduce the voltage drop in very long BTS the power can be supplied at an
intermediate position rather than at the end (see Table 6).

Calculation of voltage drop for unevenly distributed loads

If the loads cannot be considered to be evenly distributed, the voltage drop can
be calculated more accurately by using the formulas below.
L3
L2
L1
1SDC010015F0001

l1 l2 l3

L L L

For the distribution of the three-phase loads shown in the figure, the voltage
drop can be calculated by the following formula if the BTS has a constant cross
section (as usual):

u = 3[ rt ( I 1L1 cos 1+ I 2 L2 cos 2 + I 3 L3 cos 3 ) + x( I 1L1 sin 1 + I 2 L2 sin 2 + I 3 L3 sin 3 )]

ABB SACE - Electrical devices 99

 2.6 Busbar trunking systems

2 Protection of feeders
Generally speaking, this formula becomes:

3 rt . I i . Li . cos mi + x . I i . Li . sin mi
u = [V] (8)
1000

where:
rt is the phase resistance per unit of length of BTS, measured under thermal
steady-state conditions [m/m];
x is the phase reactance per unit of length of BTS [m/m];
cosm is average power factor of the i-th load;
Ii is i-th load current [A];
Li is the distance of the i-th load from the beginning of the BTS [m].

Joule-effect losses
Joule-effect losses are due to the electrical resistance of the BTS.
The losses are dissipated in heat and contribute to the heating of the trunking
and of the environment. Calculation of power losses is useful for correctly
dimensioning the air-conditioning system for the building.
Three-phase losses are:

3 . rt . I b2 . L
Pj = [W] (9a)
1000

while single-phase losses are:

2 . rt . I b2 . L
Pj = [W] (9b)
1000

where:
Ib is the current used [A];
rt is the phase resistance per unit of length of BTS measured under thermal
steady-state conditions [m/m];
L is the length of BTS [m].
For accurate calculations, losses must be assessed section by section on the
basis of the currents flowing through them; e.g. in the case of distribution of
loads shown in the previous figure:

Length Current Losses

1 section L1 I1+I2+I3 P1=3rtL1(I1+I2+I3)2
2 section L2-L1 I2+I3 P2=3rt(L2-L1)(I2+I3)2
3 section L3-L2 I3 P3=3rt(L3-L2)(I3)2
Total losses in BTS Ptot=P1+P2+P3

100 ABB SACE - Electrical devices

 3 Protection of electrical equipment

3.1 Protection and switching of lighting

circuits
Introduction
Upon supply of a lighting installation, for a brief period an initial current exceeding
the rated current (corresponding to the power of the lamps) circulates on the
network. This possible peak has a value of approximately 1520 times the
rated current, and is present for a few milliseconds; there may also be an inrush
current with a value of approximately 1.53 times the rated current, lasting up
to some minutes. The correct dimensioning of the switching and protection
devices must take these problems into account.

Peak current diagram Inrush current diagram

I [A] I [A]

Peak
1520 In

1SDC010003F0901
Inrush

1.53 In
In

4-5 milliseconds Time [milliseconds] 3- 5 min. Time [minutes]

The most commonly used lamps are of the following types:

- incandescent;
- halogen;
- fluorescent;
- high intensity discharge: mercury vapour, metal halide and sodium vapour.

Incandescent lamps
Incandescent lamps are made up of a glass bulb containing a vacuum or inert
gas and a tungsten filament. The current flows through this filament, heating it
until light is emitted.
The electrical behaviour of these lamps involves a high peak current, equal to
approximately 15 times the rated current; after a few milliseconds the current
returns to the rated value. The peak is caused by the lamp filament which,
initially cold, presents a very low electrical resistance. Subsequently, due to the
very fast heating of the element, the resistance value increases considerably,
causing the decrease in the current absorbed.

ABB SACE - Electrical devices 101

 3.1 Protection and switching of lighting circuits

3 Protection of electrical equipment

Halogen lamps
Halogen lamps are a special type of incandescent lamp in which the gas
contained within the bulb prevents the vaporized material of the tungsten filament
from depositing on the surface of the bulb and forces re-deposition on the
filament. This phenomenon slows the deterioration of the filament, improves
the quality of the light emitted and increases the life of the lamp.
The electrical behaviour of these lamps is the same as that of incandescent
lamps.

Fluorescent lamps
Fluorescent lamps are a so-called discharge light source. The light is produced
by a discharge within a transparent enclosure (glass, quartz, etc. depending on
the type of lamp) which contains mercury vapour at low pressure.
Once the discharge has started, the gas within the enclosure emits energy in
the ultraviolet range which strikes the fluorescent material; in turn, this material
transforms the ultraviolet radiation into radiation which has a wavelength within
the visible spectrum. The colour of the light emitted depends upon the fluorescent
material used.
The discharge is created by an appropriate peak in voltage, generated by a
starter. Once the lamp has been switched on, the gas offers an ever lower
resistance, and it is necessary to stabilize the intensity of the current, using a
controller (reactor); this lowers the power factor to approximately 0.40.6;
normally a capacitor is added to increase the power factor to a value of more
than 0.9
There are two types of controllers, magnetic (conventional) and electronic, which
absorb from 10% to 20% of the rated power of the lamp. Electronic controllers
offer specific advantages such as a saving in the energy absorbed, a lower
dissipation of heat, and ensure a stable, flicker-free light. Some types of
fluorescent lamps with electronic reactors do not need a starter.
Compact fluorescent lamps are made up of a folded tube and a plastic base
which contains, in some cases, a conventional or electronic controller.
The value of the inrush current depends upon the presence of a power factor
correction capacitor:
- non PFC lamps have inrush currents equal to approximately twice the rated
current and a turn-on time of about ten seconds;
- in PFC lamps, the presence of the capacitor allows the reduction of the turn-
on time to a few seconds, but requires a high peak current, determined by
the charge of the capacitor, which can reach 20 times the rated current.
If the lamp is fitted with an electronic controller, the initial transient current may
lead to peak currents equal to, at maximum, 10 times the rated current.

102 ABB SACE - Electrical devices

 3.1 Protection and switching of lighting circuits

3 Protection of electrical equipment

High intensity discharge lamps: mercury vapour, metal
halide and sodium vapour
The functioning of high intensity discharge lamps is the same as that of
fluorescent lamps with the difference that the discharge occurs in the presence
of a gas at high pressure. In this case, the arc is able to vaporize the metallic
elements contained in the gas, releasing energy in the form of radiation which
is both ultraviolet and within the visible spectrum. The special type of bulb
glass blocks the ultraviolet radiation and allows only the visible radiation to
pass through. There are three main types of high intensity discharge lamps:
mercury vapour, metal halide and sodium vapour. The colour characteristics
and the efficiency of the lamp depend upon the different metallic elements
present in the gas, which are struck by the arc.
High intensity discharge lamps require a suitably sized controller and a heating
period which can last some minutes before the emission of the rated light output.
A momentary loss of power makes the restarting of the system and the heating
necessary.
Non PFC lamps have inrush currents of up to twice the rated current for
approximately 5 minutes.
PFC lamps have a peak current equal to 20 times the rated current, and an
inrush current of up to twice the rated current for approximately 5 minutes.

Lamp type Peak current Inrush current Turn-on time

Incandescent lamps 15In - -
Halogen lamps 15In - -
Fluorescent Non PFC 2In 10 s
lamp PFC 20In 16 s
High intensity Non PFC 2In 28 min
discharge lamps PFC 20In 2In 28 min

Protection and switching devices

IEC 60947-4-1 identifies two specific utilization categories for lamp control
contactors:
AC-5a switching of electric discharge lamps;
AC-5b switching of incandescent lamps.
The documentation supplied by the manufacturer includes tables for contactor
selection, according to the number of lamps to be controlled, and to their type.

ABB SACE - Electrical devices 103

 3.1 Protection and switching of lighting circuits

3 Protection of electrical equipment

For the selection of a protection device the following verifications shall be carried
out:

- the trip characteristic curve shall be above the turning-on characteristic curve
of the lighting device to avoid unwanted trips; an approximate example is
shown in Figure1;

- coordination shall exist with the contactor under short-circuit conditions (lighting
installations are not generally characterized by overloads).

With reference to the above verification criteria, the following tables show the
maximum number of lamps per phase which can be controlled by the
combination of ABB circuit breakers and contactors for some types of lamps,
according to their power and absorbed current Ib1 , for three phase installations
with a rated voltage of 400 V and a maximum short-circuit current of 15 kA.

1
For calculation see Annex B Calculation of load current Ib

Table 1: Incandescent and halogen lamps

Ur= 400 V Ik= 15 kA

Incandescent/halogen lamps
Circuit-Breaker type S270 D20 S270 D20 S270 D25 S270 D32 S270 D50 T2N160 In63
Setting PR221 DS ---- ---- ---- ---- ---- L= 0.68- A S= 8- B L=
Contactor type A26 A26 A26 A26 A30 A40
Rated Power [W] Rated current Ib [A] N lamps per ph
60 0.27 57 65 70 103 142 155
100 0.45 34 38 42 62 85 93
200 0.91 17 19 20 30 42 46
300 1.37 11 12 13 20 28 30
500 2.28 6 7 8 12 16 18
1000 4.55 3 4 4 6 8 9

104 ABB SACE - Electrical devices

 3.1 Protection and switching of lighting circuits

3 Protection of electrical equipment

Figure 1: Approximate diagram for the coordination of lamps with
protection and switching devices

[t]

Contactor Icw

Turning-on characteristics

1SDC010004F0901
[A]

Circuit-breaker characteristics

S270 D32 S270 D50 T2N160 In63 T2N160 In63 T2N160 In100 T2N160 In100 T2N160 In100 T2N160 In160
---- ---- L= 0.68- A S= 8- B L= 0.92- A S= 10- B L= 0.68- A S= 8- B L= 0.76- A S= 8- B L= 1- A S= 10- B L= 0.68- A S= 7- B
A26 A30 A40 A50 A63 A75 A95 A110
N lamps per phase
103 142 155 220 246 272 355 390
62 85 93 132 147 163 210 240
30 42 46 65 73 80 105 120
1SDC010032F0201

20 28 30 43 48 53 70 80
12 16 18 26 29 32 42 48
6 8 9 13 14 16 21 24

ABB SACE - Electrical devices 105

 3.1 Protection and switching of lighting circuits

3 Protection of electrical equipment

Table 2: Fluorescent lamps
Ur= 400 V Ik= 15 kA

Fluorescent lamps non PFC

Circuit-Breaker type S270 D16 S270 D20 S270 D20 S270 D32 S270 D40 S270 D50
Setting PR221 DS
Contactor type A26 A26 A26 A26 A30 A40
Rated Power [W] Rated current Ib [A] N lamps per
20 0.38 40 44 50 73 100 110
40 0.45 33 37 42 62 84 93
65 0.7 21 24 27 40 54 60
80 0.8 18 21 23 35 47 52
100 1.15 13 14 16 24 33 36
110 1.2 12 14 15 23 31 35

Ur= 400 V Ik= 15 kA

Fluorescent lamps PFC

Circuit-Breaker type S270 D25 S270 D25 S270 D32 S270 D40 S270 D63 T2N160 In63
Setting PR221 DS --- --- --- --- --- L= 0.68- A S= 8- B
Contactor type A26 A26 A26 A26 A30 A40
Rated Power [W] Rated current Ib [A] Capacitor [F] N lamps per
20 0.18 5 83 94 105 155 215 233
40 0.26 5 58 65 75 107 150 160
65 0.42 7 35 40 45 66 92 100
80 0.52 7 28 32 36 53 74 80
100 0.65 16 23 26 29 43 59 64
110 0.7 18 21 24 27 40 55 59

106 ABB SACE - Electrical devices

 3.1 Protection and switching of lighting circuits

3 Protection of electrical equipment

0 S270 D32 S270 D40 S270 D50 S270 D63 T2N160 In100 T2N160 In100 T2N160 In100 T2N160 In160
L= 0.68- A S= 10- B L= 0.76- A S= 10- B L= 0.96- A- S= 10- B S= 0.68- A S= 10- B
A26 A30 A40 A50 A63 A75 A95 A110
N lamps per phase
73 100 110 157 173 192 250 278
62 84 93 133 145 162 210 234
40 54 60 85 94 104 135 150

1SDC010033F0201
35 47 52 75 82 91 118 132
24 33 36 52 57 63 82 92
23 31 35 50 55 60 79 88

S270 D40 S270 D63 T2N160 In63 T2N160 In63 T2N160 In100 T2N160 In100 T2N160 In100
--- --- L= 0.68- A S= 8- B L= 1- A S= 10- B L= 0.68- A S= 10- B L= 0.76- A S= 10- B L= 0.96- A S= 10- B
A26 A30 A40 A50 A63 A75 A95
N lamps per phase
155 215 233 335 360 400 530
107 150 160 230 255 280 365
66 92 100 142 158 173 225
53 74 80 115 126 140 180
43 59 64 92 101 112 145
40 55 59 85 94 104 135

ABB SACE - Electrical devices 107

 3.1 Protection and switching of lighting circuits

3 Protection of electrical equipment

Table 3: High intensity discharge lamps

Ur= 400 V Ik= 15 kA

Fluorescent lamps non PFC
Circuit-Breaker type S270 D16 S270 D2 S270 D20 S270 D32 S270 D40 S270 D40
Setting PR221 DS
Contactor type A26 A26 A26 A26 A30 A40
Rated Power [W] Rated current Ib [A] N lamps per ph
150 1.8 6 7 8 11 15 17
250 3 4 4 5 7 9 10
400 4.4 3 3 3 4 6 7
600 6.2 1 2 2 3 4 5
1000 10.3 - 1 1 2 3 3

Ur= 400 V Ik= 15 kA

Fluorescent lamps PFC
Circuit-Breaker type S270 D16 S270 D20 S270 D20 S270 D32 S270 D40 S270 D40
Setting PR221 DS --- --- --- --- --- --- L
Contactor type A26 A26 A26 A26 A30 A40
Rated Power [W] Rated current Ib [A] Capacitor [F] N lamps per ph
150 1 20 13 14 15 23 28 30
250 1.5 36 8 9 10 15 18 20
400 2.5 48 5 5 6 9 11 12
600 3.3 65 4 4 5 7 8 9
1000 6.2 100 - - - 4 4 5

108 ABB SACE - Electrical devices

 3.1 Protection and switching of lighting circuits

3 Protection of electrical equipment

S270 D32 S270 D40 S270 D40 S270 D50 S270 D63 T2N160 In100 T2N160 In100 T2N160 In160
L= 0.8- B S= 6.5- B L= 1- B S= 8- B L= 0.8- B S= 6.5- B
A26 A30 A40 A50 A63 A75 A95 A110
N lamps per phase
11 15 17 23 26 29 38 41
7 9 10 14 16 17 23 25
4 6 7 9 10 12 15 17
3 4 5 7 8 8 11 12
2 3 3 4 5 5 6 7

S270 D32 S270 D40 S270 D40 T2N160 In100 T2N160 In100 T2N160 In100 T2N160 In160 T2N160 In160
--- --- --- L= 0.8- B S= 6.5- B L= 0.88- B S= 6.5- B L= 1- B S= 6.5- B L= 0.84- B S= 4.5- B L= 0.88- B S= 4.5- B
A26 A30 A40 A50 A63 A75 A95 A110
N lamps per phase
23 28 30 50 58 63 81 88 1SDC010034F0201
15 18 20 33 38 42 54 59
9 11 12 20 23 25 32 36
7 8 9 15 17 19 24 27
4 4 5 8 9 10 13 14

Example:
Switching and protection of a lighting system, supplied by a three phase network
at 400 V 15 kA, made up of 55 incandescent lamps, of 200 W each, per phase.
In table 1, on the row corresponding to 200 W, select the cell showing the
number of controllable lamps immediately above the number of lamps per phase
present in the installation. In the specific case, corresponding to the cell for 65
lamps per phase the following equipment are suggested:
- ABB Tmax T2N160 In63 circuit breaker with PR221/DS type electronic release,
with protection L set at 0.92, curve A and protection S set at 10, curve B;
- A50 contactor.

ABB SACE - Electrical devices 109

 3 Protection of electrical equipment

3.2 Protection and switching of generators

The need to guarantee an ever greater continuity of service has led to an increase
in the use of emergency supply generators, either as an alternative to, or in
parallel with the public utility supply network.

Typical configurations include:

Island supply (independent functioning) of the priority loads in the case of a
lack of energy supply through the public network;
Supply to the user installation in parallel with the public supply network.

Unlike the public supply network, which has a constant contribution, in case of
a short-circuit, the current supplied by the generator is a function of the
parameters of the machine itself, and decreases with time; it is possible to
identify the following successive phases:
1. a subtransient phase: with a brief duration (1050 ms), characterized
by the subtransient reactance Xd (520% of the rated impedance value),
and by the subtransient time constant Td (530 ms);
2. a transitory phase: may last up to some seconds (0.52.5 s), and is
characterized by the transitory reactance Xd (1540% of the rated
impedance value), and by the transitory time constant Td (0.032.5 s);
3. a synchronous phase: may persist until the tripping of external protection,
and is characterized by the synchronous reactance Xd (80300% of
the rated impedance value).

t [s] 101
Synchronous
phase

Transient
phase

10-1

Subtransient
phase
10-2
1SDC010018F0201

10-3
1 10 102
x Irg

110 ABB SACE - Electrical devices

 3.2 Protection and switching of generators

3 Protection of electrical equipment

As a first approximation, it can be estimated that the maximum value of the
short-circuit current of a generator, with rated power Srg, at the rated voltage of
the installation Ur, is equal to:
Irg . 100
Ikg =
X 'd' %
where
Irg is the rated current of the generator:
Srg
Irg =
3 . Ur
The circuit breaker for the protection of the generator shall be selected according
to the following criteria:
the set current higher than the rated current of the generator: I1 Irg;
breaking capacity Icu or Ics higher than the maximum value of short-circuit
current at the installation point:
- in the case of a single generator: Icu(Ics) Ikg;
- in the case of n identical generators in parallel: Icu(Ics) Ikg(n-1);
- in the case of operation in parallel with the network: Icu(Ics) IkNet,
as the short-circuit contribution from the network is normally
greater than the contribution from the generator;
for circuit breakers with thermomagnetic releases: low magnetic trip threshold:
I3 =2.5/3In;
for circuit breakers with electronic releases:
- trip threshold of the delayed short-circuit protection function (S), set
between 1.5 and 4 times the rated current of the generator, in such
away as to intercept the decrement curve of the generator:
I2 = (1.54)Irg; if the function S is not present, function I can be set
at the indicated values I3 = (1.54)Irg;
- trip threshold of the instantaneous short-circuit protection function
(I) set at a value greater than the rated short-circuit current of the
generator, so as to achieve discrimination with the devices installed
downstream, and to allow fast tripping in the event of a short-circuit
upstream of the device (working in parallel with other generators or
with the network):

I 3 I kg

ABB SACE - Electrical devices 111

 3.2 Protection and switching of generators

3 Protection of electrical equipment

The following tables give ABB SACE suggestions for the protection and switching
of generators; the tables refer to 400 V (Table 1), 440 V (Table 2), 500 V (Table 3)
and 690 V (Table 4).

Table 1 400 V Table 2 440 V

Srg [kVA] MCB MCCB ACB Srg [kVA] MCB MCCB ACB
4 S20L/S260 B6 4 S20L/S260 B6
6 T2 160 In=10 6 S20L/S260 B8 T2 160 In=10
S20L/S260 B10
7 7 S20L/S260 B10
9 S20L/S260 B13 9 S20L/S260 B13
11 S20L/S260 B16 11 S20L/S260 B16
T2 160 In=25 T2 160 In=25
14 14 S20L/S260 B20
S20L/S260 B25
17 17 S20L/S260 B25
19 19
21 S20L/S260 B32 21 S20L/S260 B32
22 22
28 28 S20L/S260 B40
S20L/S260 B50 T2 160 In=63
31 31
S20L/S260 B50 T2 160 In=63
35 35
38 S20L/S260 B63 38
42 42 S20L/S260 B63
44 44
48 S280 B80 48
T2 160 In=100 S280 B80
55 55
69 T2 160 In=100
S280 B100 69 S280 B100
80 80
T2 160 In=160 T2 160 In=160
87 87
100 T2 160 100
T2 160 In=160
111 111
T4 250
138 138 T4 250
159 T3 250 159 T3 250
173 T4 250 173 T4 250
180 180
190 190
T4 320
208 208 T4 320
218 218
242 242
T5 400
277 277 T5 400
308 308
311 311
346 T5 630 346 T5 630
381 S6 800 381 S6 800
415 415
436 436
484 S6 800 484 S6 800
554 S7 1250 554 S7 1000
E1/E2 1250
692 692 E1/E2 1250
727 S7 1000
S7 1250 727
865 E2/E3 1600 865 S7 1250
1107 S7 1600 E2/E3 2000 1107 S7 1600 E2/E3 1600
1730 E3 3200 1730 E3 2500
2180 S8 3200 E3 3200/E4 4000 2180 S8 3200
1SDC010016F0001

2214 2214 E3 3200

2250 E4 4000 2250
2500 2500 E4 3600
2800 2800 E4 4000
3150 E6 5000/6300 3150
E6 5000/6300
3500 3500

112 ABB SACE - Electrical devices

 3.2 Protection and switching of generators

3 Protection of electrical equipment

Table 3 500 V Table 4 690 V

Srg [kVA] MCB MCCB ACB MCB MCCB ACB

4 4
6 T2 160 In=10 6
7 7 T2 160 In=10
9 9
11 11
14 14
T2 160 In=25
17 17
19 19
T2 160 In=25
21 21
22 22
28 28
31 31
35 35
T2 160 In=63
38 38
42 42
T2 160 In=63
44 44
48 48
55 55
69 T2 160 In=100 69
80 80
87 87
T2 160 In=100
100 100
T2 160 In=160 111
111
138 138
159 T3 250 159 T2 160 In=160
173 T4 250 173
180 180
T3 250
190 T4 250 190
208 208
218 218
T4 250
242 T4 320 242
277 277
308 308
311 T5 400 311
T4 320
346 346
381 381
415 T5 630 415
T5 400
436 S6 800 436
484 484 T5 630
554 S6 800 554
T5 630
692 S7 1000 E1/E2 1250 692 E1 800
S6 800
727 727
S7 1250
865 865 S6 800
1107 S7 1600 E2/E3 1600 1107 S7 1000 E1/E2 1250
1730 S8 2500 E3 2500 1730 S7 1600 E2/E3 1600
2180 2180
1SDC010017F0001

E2 2000
2214 2214
S8 3200 E3 3200 E3 2500
2250 2250 S8 2500
2500 2500
E3 2500
2800 2800
E4 4000
3150 3150
S8 3200 E3 3200
3500 E6 5000/6300 3500
Note: It is always advisable to check that the settings of the releases are correct with respect to the
effective decrement curve of the current of the generator to be protected.

ABB SACE - Electrical devices 113

 3.2 Protection and switching of generators

3 Protection of electrical equipment

Example:
Protection of a generator with Srg = 100 kVA, in a system with a rated voltage
of 440 V
The generator parameters are:
Ur = 440 V
Srg = 100 kVA
f = 50 Hz
Irg = 131.2 A
Xd = 6.5 % (subtransient reactance)
Xd = 17.6 % (transient reactance)
Xd = 230 % (synchronous reactance)
Td = 5.5 ms (subtransient time constant)
Td = 39.3 ms (transient time constant)

From table 2, an ABB SACE T2N160 circuit-breaker is selected, with In = 160

A, with electronic release PR221-LS. For correct protection of the generator,
the following settings are selected:

function L: 0.84 A, corresponding to 134.4 A, value greater than Irg .

function I: 1.5

Time-Current Curves
10 4 s

10 3 s
T2 160

10 2 s

10 1 s

1s
100 kVA generator
decrement curve
-1
10 s
1SDC010019F0201

10-2s

10-1kA 1kA 101kA

114 ABB SACE - Electrical devices

 3 Protection of electrical equipment

3.3 Protection and switching of motors

Electromechanical starter
The starter is designed to:
- start motors;
- ensure continuous functioning of motors;
- disconnect motors from the supply line;
- guarantee protection of motors against working overloads.
The starter is typically made up of a switching device (contactor) and an overload
protection device (thermal release).
The two devices must be coordinated with equipment capable of providing
protection against short-circuit (typically a circuit breaker with magnetic release
only), which is not necessarily part of the starter.

The characteristics of the starter must comply with the international Standard
IEC 60947-4-1, which defines the above as follows:

Contactor: a mechanical switching device having only one position of rest,

operated otherwise than by hand, capable of making, carrying and breaking
currents under normal circuit conditions including operating overload conditions.

Thermal release: thermal overload relay or release which operates in the case
of overload and also in case of loss of phase.

Circuit-breaker: defined by IEC 60947-2 as a mechanical switching device,

capable of making, carrying and breaking currents under normal circuit
conditions and also making, carrying for a specified time and breaking currents
under specified abnormal circuit conditions.

The main types of motor which can be operated and which determine the
characteristics of the starter are defined by the following utilization categories:

Table 1: Utilization categories and typical applications

Current type Utilization categories Typical applications
Slip-ring motors: starting,
AC-2
switching off
Alternating Current ac Squirrel-cage motors: starting,
AC-3
switching off during running(1)
Squirrel-cage motors: starting,
AC-4
plugging, inching
(1)
AC-3 categories may be used for occasionally inching or plugging for limited time periods
such as machine set-up; during such limited time periods the number of such operations
should not exceed five per minutes or more than ten in a 10 minutes period.

ABB SACE - Electrical devices 115

 3.3 Protection and switching of motors

3 Protection of electrical equipment

The choice of the starting method and also, if necessary, of the type of motor to
be used depends on the typical resistant torque of the load and on the short-
circuit power of the motor supplying network.

With alternating current, the most commonly used motor types are as follows:
- asynchronous three-phase squirrel-cage motors (AC-3): the most widespread
type due to the fact that they are of simple construction, economical and
sturdy; they develop high torque with short acceleration times, but require
elevated starting currents;
- slip-ring motors (AC-2): characterized by less demanding starting conditions,
and have quite a high starting torque, even with a supply network of low
power.

Starting methods
The most common starting methods for asynchronous squirrel-cage motors
are detailed below:

Direct starting
With direct starting, the DOL (Direct On Line) starter, with the closing of line
contactor KL, the line voltage is applied to the motor terminals in a single
operation. Hence a squirrel-cage motor develops a high starting torque with a
relatively reduced acceleration time. This method is generally used with small
and medium power motors which reach full working speed in a short time.
These advantages are, however, accompanied by a series of drawbacks,
including, for example:
- high current consumption and associated voltage drop which may cause
damages to the other parts of the system connected to the network;
- violent acceleration which has negative effects on mechanical transmission
components (belts, chains and mechanical joints), reducing working life.

MCCB

KL

TOR
1SDC010018F0001

Motor

116 ABB SACE - Electrical devices

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3 Protection of electrical equipment

Other types of starting for squirrel-cage motors are accomplished by reducing
the supply voltage of the motor: this leads to a reduction in the starting current
and of the motor torque, and an increase in the acceleration time.

Star-Delta starter
The most common reduced voltage starter is the Star-Delta starter (Y-), in
which:
- on starting, the stator windings are star-connected, thus achieving the
reduction of peak inrush current;
- once the normal speed of the motor is nearly reached, the switchover to delta
is carried out.
After the switchover, the current and the torque follow the progress of the curves
associated with normal service connections (delta).

As can be easily checked, starting the motor with star-connection gives a voltage
reduction of 3, and the current absorbed from the line is reduced by 1/3
compared with that absorbed with delta-connection.
The start-up torque, proportional to the square of the voltage, is reduced by 3
times, compared with the torque that the same motor would supply when del-
ta-connected.
This method is generally applied to motors with power from 15 to 355 kW, but
intended to start with a low initial resistant torque.

MCCB

KL K

KY

TOR
1SDC010019F0001

Motor

Starting sequence
By pressing the start button, contactors KL and KY are closed. The timer starts
to measure the start time with the motor connected in star. Once the set time
has elapsed, the first contact of the timer opens the KY contactor and the
second contact, delayed by approximately 50 ms, closes the K contactor.
With this new configuration, contactors KL and K closed, the motor becomes
delta-connected.

ABB SACE - Electrical devices 117

 3.3 Protection and switching of motors

3 Protection of electrical equipment

The thermal release TOR, inserted in the delta circuit, can detect any 3rd harmonic
currents, which may occur due to saturation of the magnetic pack and by
adding to the fundamental current, overload the motor without involving the line.

With reference to the connection diagram, the equipment used for a Star/Delta
starter must be able to carry the following currents:
Ir
KL line contactor and K delta contactor
3

Ir
KY star contactor
3

Ir
overload protection release
3
where Ir is the rated current of the motor.

Starting with autotransformers

Starting with autotransformers is the most functional of the methods used for
reduced voltage starting, but is also the most expensive. The reduction of the
supply voltage is achieved by using a fixed tap autotransformer or a more
expensive multi tap autotransformer.
Applications can be found with squirrel-cage motors which generally have a
power from 50 kW to several hundred kilowatts, and higher power double-
cage motors.

MCCB

K2 K3 K1
1SDC010020F0001

TOR

Motor

The autotransformer reduces the network voltage by the factor K (K=1.251.8),

and as a consequence the start-up torque is reduced by K2 times compared
with the value of the full rated voltage.
On starting, the motor is connected to the taps of the autotransformer and the
contactors K2 and K1 are closed.

118 ABB SACE - Electrical devices

 3.3 Protection and switching of motors

3 Protection of electrical equipment

Therefore, the motor starts at a reduced voltage, and when it has reached
approximately 80% of its normal speed, contactor K1 is opened and main
contactor K3 is closed. Subsequently, contactor K2 is opened, excluding the
autotransformer so as to supply the full network voltage.

Starting with inductive reactors or resistors

This type of starting is used for simple or double-cage rotors. The reduction of
the supply voltage is achieved by the insertion of inductive reactors or resistors,
in series to the stator. On start-up, the current is limited to 2.53.5 times the
rated value.
On starting, the motor is supplied via contactor K2; once the normal speed is
reached, the reactors are short-circuited by the closing of contactor K1, and
are then excluded by the opening of contactor K2.
It is possible to achieve exclusions by step of the resistors or reactors with
time-delayed commands, even for motors with power greater than 100 kW.
The use of reactors notably reduces the power factor, while the use of resistors
causes the dissipation of a high power (Joule effect), even if limited to the
starting phase.
For a reduction K (0.60.8) of the motor voltage, the torque is reduced by K2
times (0.360.64).

K1 K2

Inductance
1SDC010021F0001

TOR

Motor

In compliance with the above mentioned Standard, starters can also be classified
according to tripping time (trip classes), and according to the type of coordination
achieved with the short-circuit protection device (Type 1 and Type 2).

ABB SACE - Electrical devices 119

 3.3 Protection and switching of motors

3 Protection of electrical equipment

Trip classes
The trip classes differentiate between the thermal releases according to their
trip curve.
The trip classes are defined in the following table 2:

Table 2: Trip class

Trip Class Tripping time in seconds (Tp)
10A 2 < Tp 10
10 4 < Tp 10
20 6 < Tp 20
30 9 < Tp 30

where Tp is the cold trip time of the thermal release at 7.2 times the set current
value (for example: a release in class 10 at 7.2 times the set current value must
not trip within 4 s, but must trip within 10 s).
It is normal procedure to associate class 10 with a normal start-up type, and
class 30 with a heavy duty start-up type.

Coordination type
Type 1
It is acceptable that in the case of short-circuit the contactor and the thermal
release may be damaged. The starter may still not be able to function and must
be inspected; if necessary, the contactor and/or the thermal release must be
replaced, and the breaker release reset.

Type 2
In the case of short-circuit, the thermal release must not be damaged, while
the welding of the contactor contacts is allowed, as they can easily be separated
(with a screwdriver, for example), without any significant deformation.

In order to clearly determine a coordination type, and therefore the equipment

necessary to achieve it, the following must be known:
power of the motor in kW and type;
rated system voltage;
rated motor current;
short-circuit current at installation point;
starting type: DOL or Y/ - normal or heavy duty Type 1 or Type 2.

The requested devices shall be coordinated with each other in accordance

with the prescriptions of the Standard.
For the most common voltages and short-circuit values (400 V - 440 V - 500 V
- 690 V 35 kA - 50 kA) and for the most frequently used starting types, such as
direct starting and Star/Delta starting, for asynchronous squirrel-cage motor
(AC-3), ABB supplies solutions with:
magnetic circuit-breaker - contactor - thermal release;
thermomagnetic circuit-breaker - contactor;
thermomagnetic circuit-breaker with PR212 MP electronic release contactor.

120 ABB SACE - Electrical devices

 3.3 Protection and switching of motors

3 Protection of electrical equipment

The following is an example of the type of tables available:

Table 3: 400 V 50 kA DOL Normal Type 2

(Tmax, Isomax Contactor Thermal release)
Motor MCCB Contactor Thermal Overload Relay

Current
setting

Pe Ir Type I3 Type Type min. max.

[kW] [A] [A] [A] [A]

0.37 1.1 T2S160 MF 1.6 21 A9 TA25DU1.4 1 1.4
0.55 1.5 T2S160 MF 1.6 21 A9 TA25DU1.8 1.3 1.8
0.75 1.9 T2S160 MF 2 26 A9 TA25DU2.4 1.7 2.4
1.1 2.8 T2S160 MF 3.2 42 A9 TA25DU4 2.8 4
1.5 3.5 T2S160 MF 4 52 A16 TA25DU5 3.5 5
2.2 5 T2S160 MF 5 65 A26 TA25DU6.5 4.5 6.5
3 6.6 T2S160 MF 8.5 110 A26 TA25DU8.5 6 8.5
4 8.6 T2S160 MF 11 145 A30 TA25DU11 7.5 11
5.5 11.5 T2S160 MF 12.5 163 A30 TA25DU14 10 14
7.5 15.2 T2S160 MA 20 210 A30 TA25DU19 13 19
11 22 T2S160 MA 32 288 A30 TA42DU25 18 25
15 28.5 T2S160 MA 52 392 A50 TA75DU42 29 42
18.5 36 T2S160 MA 52 469 A50 TA75DU52 36 52
22 42 T2S160 MA 52 547 A50 TA75DU52 36 52
30 56 T2S160 MA 80 840 A63 TA75DU80 60 80
37 68 T2S160 MA 80 960 A75 TA75DU80 60 80
45 83 T2S160 MA 100 1200 A95 TA110DU110 80 110
55 98 T3S250 MA 160 1440 A110 TA110DU110 80 110
75 135 T3S250 MA 200 1800 A145 TA200DU175 130 175
90 158 T3S250 MA 200 2400 A185 TA200DU200 150 200
110 193 T4S320 PR221-I In320 2720 A210 E320DU320 100 320
132 232 T5S400 PR221-I In400 3200 A260 E320DU320 100 320
160 282 T5S400 PR221-I In400 4000 A300 E320DU320 100 320
1SDC010022F0201

200 349 T5S630 PR221-I In630 5040 AF400 E500DU500 150 500
250 430 T5S630 PR221-I In630 6300 AF460 E500DU500 150 500
290 520 S6S800 PR211-I In800 8000 AF580 E800DU800 250 800
315 545 S6S800 PR211-I In800 9600 AF580 E800DU800 250 800
355 610 S6S800 PR211-I In800 9600 AF750 E800DU800 250 800
MA: magnetic only adjustable release
MF: fixed magnetic only release

ABB SACE - Electrical devices 121

 3.3 Protection and switching of motors

3 Protection of electrical equipment

Table 4: 400 V 50 kA DOL Heavy duty Type 2
(Tmax, Isomax Contactor Thermal release)
Motor MCCB Contactor Thermal Overload Relay

Setting of No. of Setting

the turns of range
Type magnetic Type Type** the CT
Pe Ir release primary min. max.
[kW] [A] [A]
coil [A] [A]
0.37 1.1 T2S160 MF 1.6 21 A9 TA25DU1.4* 1 1.4
0.55 1.5 T2S160 MF 1.6 21 A9 TA25DU1.8* 1.3 1.8
0.75 1.9 T2S160 MF 2 26 A9 TA25DU2.4* 1.7 2.4
1.1 2.8 T2S160 MF 3.2 42 A9 TA25DU4* 2.8 4
1.5 3.5 T2S160 MF 4 52 A16 TA25DU5* 3.5 5
2.2 5 T2S160 MF 5 65 A26 TA25DU6.5* 4.5 6.5
3 6.6 T2S160 MF 8.5 110 A26 TA25DU8.5* 6 8.5
4 8.6 T2S160 MF 11 145 A30 TA25DU11* 7.5 11
5.5 11.5 T2S160 MF 12.5 163 A30 TA450SU60 4 10 15
7.5 15.2 T2S160 MA 20 210 A30 TA450SU60 3 13 20
11 22 T2S160 MA 32 288 A30 TA450SU60 2 20 30
15 28.5 T2S160 MA 52 392 A50 TA450SU80 2 23 40
18.5 36 T2S160 MA 52 469 A50 TA450SU80 2 23 40
22 42 T2S160 MA 52 547 A50 TA450SU60 40 60
30 56 T2S160 MA 80 840 A63 TA450SU80 55 80
37 68 T2S160 MA 80 960 A95 TA450SU80 55 80
45 83 T2S160 MA 100 1200 A110 TA450SU105 70 105
55 98 T3S250 MA 160 1440 A145 TA450SU140 95 140
75 135 T3S250 MA 200 1800 A185 TA450SU185 130 185
90 158 T3S250 MA 200 2400 A210 TA450SU185 130 185
110 193 T4S320 PR221-I In320 2720 A260 E320DU320 100 320
132 232 T5S400 PR221-I In400 3200 A300 E320DU320 100 320
160 282 T5S400 PR221-I In400 4000 AF400 E500DU500 150 500 1SDC010020F0201

200 349 T5S630 PR221-I In630 5040 AF460 E500DU500 150 500
250 430 T5S630 PR221-I In630 6300 AF580 E500DU500*** 150 500
290 520 S6S800 PR211-I In800 8000 AF750 E800DU800 250 800
315 545 S6S800 PR211-I In800 9600 AF750 E800DU800 250 800
355 610 S6S800 PR211-I In800 9600 AF750 E800DU800 250 800

* Provide a by-pass contactor of the same size during motor start-up

** For type E releases choose tripping class 30
*** Connecting kit not available. To use the connecting kit, replacement with release E800DU800 is necessary
MA: magnetic only adjustable release
MF: fixed magnetic only release

122 ABB SACE - Electrical devices

 3.3 Protection and switching of motors

3 Protection of electrical equipment

Table 4: 400 V 50 kA Y/ Normal Type 2
(Tmax, Isomax Contactor Thermal release)

MOTOR MCCB Contactor Thermal Overload Relay

I3 LINE DELTA STAR

Pe [kW] Ir [A] Type [A] Type Type Type Type [A]
18.5 36 T2S160 MA52 469 A50 A50 A26 TA75DU25 18-25
22 42 T2S160 MA52 547 A50 A50 A26 TA75DU32 22-32
30 56 T2S160 MA80 720 A63 A63 A30 TA75DU42 29-42
37 68 T2S160 MA80 840 A75 A75 A30 TA75DU52 36-52
45 83 T2S160 MA100 1050 A75 A75 A30 TA75DU63 45 - 63
55 98 T2S160 MA100 1200 A75 A75 A40 TA75DU63 45 - 63
75 135 T3S250 MA160 1700 A95 A95 A75 TA110DU90 66 - 90
90 158 T3S250 MA200 2000 A110 A110 A95 TA110DU110 80 - 110

1SDC010023F0201
110 193 T3S250 MA200 2400 A145 A145 A95 TA200DU135 100 - 135
132 232 T4S320 PR221-I In320 2880 A145 A145 A110 E200DU200 60 - 200
160 282 T5S400 PR221-I In400 3600 A185 A185 A145 E200DU200 60 - 200
200 349 T5S630 PR221-I In630 4410 A210 A210 A185 E320DU320 100 - 320
250 430 T5S630 PR221-I In630 5670 A260 A260 A210 E320DU320 100 - 320

MA : magnetic only adjustable release

ABB SACE - Electrical devices 123

 3.3 Protection and switching of motors

3 Protection of electrical equipment

Table 6: 440 V 50 kA DOL Normal Type 2
(Tmax, Isomax Contactor Thermal release)

Motor MCCB Contactor Thermal Overload Relay

Current
setting
Pe Ir Type I3 Type Type min. max.
[kW] [A] [A] [A] [A]

0,37 1 T2H160 MF 1 13 A9 TA25DU1.4 1 1,4

0,55 1,4 T2H160 MF 1.6 21 A9 TA25DU1.8 1,3 1,8
0,75 1,7 T2H160 MF 2 26 A9 TA25DU2.4 1,7 2,4
1,1 2,2 T2H160 MF 2.5 33 A9 TA25DU3.1 2,2 3,1
1,5 3 T2H160 MF 3.2 42 A16 TA25DU4 2,8 4
2,2 4,4 T2H160 MF 5 65 A26 TA25DU5 3,5 5
3 5,7 T2H160 MF 6.5 84 A26 TA25DU6.5 4,5 6,5
4 7,8 T2H160 MF 8.5 110 A30 TA25DU11 7,5 11
5,5 10,5 T2H160 MF 11 145 A30 TA25DU14 10 14
7,5 13,5 T2H160 MA 20 180 A30 TA25DU19 13 19
11 19 T2H160 MA 32 240 A30 TA42DU25 18 25
15 26 T2H160 MA 32 336 A50 TA75DU32 22 32
18,5 32 T2H160 MA 52 469 A50 TA75DU42 29 42
22 38 T2H160 MA 52 547 A50 TA75DU52 36 52
30 52 T2H160 MA 80 720 A63 TA75DU63 45 63
37 63 T2H160 MA 80 840 A75 TA75DU80 60 80
45 75 T2H160 MA 100 1050 A95 TA110DU90 65 90
55 90 T4H250 PR221-I In160 1200 A110 TA110DU110 80 110
75 120 T4H250 PR221-I In250 1750 A145 E200DU200 60 200
90 147 T4H250 PR221-I In250 2000 A185 E200DU200 60 200
110 177 T4H250 PR221-I In250 2500 A210 E320DU320 100 320
132 212 T4H320 PR221-I In320 3200 A260 E320DU320 100 320
1SDC010024F0201

160 260 T5H400 PR221-I In400 3600 A300 E320DU320 100 320
200 320 T5H630 PR221-I In630 4410 AF 400 E500DU500 150 500
250 410 T5H630 PR221-I In630 5355 AF 460 E500DU500 150 500
290 448 S6H630 PR211-I In630 7560 AF 580 E500DU500* 150 500
315 500 S6H800 PR211-I In800 8000 AF 580 E800DU800 250 800
355 549 S6H800 PR211-I In800 9600 AF 580 E800DU800 250 800
* Connection kit not available
MA: magnetic only adjustable release
MF: fixed magnetic only release

124 ABB SACE - Electrical devices

 3.3 Protection and switching of motors

3 Protection of electrical equipment

Table 7: 440 V 50 kA DOL Heavy duty Type 2
(Tmax, Isomax Contactor Thermal release)
Motor MCCB Contactor Thermal Overload Relay
Type Setting of Type Type** No. of Setting
the turns of range
Pe Ir magnetic the CT
release primary min. max.
[kW] [A] [A]
coil [A] [A]
0.37 1 T2H160 MF 1 13 A9 TA25DU1.4* 1 1.4
0.55 1.4 T2H160 MF 1.6 21 A9 TA25DU1.8* 1.3 1.8
0.75 1.7 T2H160 MF 2 26 A9 TA25DU2.4* 1.7 2.4
1.1 2.2 T2H160 MF 2.5 33 A9 TA25DU3.1* 2.2 3.1
1.5 3 T2H160 MF 3.2 42 A16 TA25DU4* 2.8 4
2.2 4.4 T2H160 MF 5 65 A26 TA25DU5* 3.5 5
3 5.7 T2H160 MF 6.5 84 A26 TA25DU6.5* 4.5 6.5
4 7.8 T2H160 MF 8.5 110 A30 TA25DU11* 7.5 11
5.5 10.5 T2H160 MF 11 145 A30 TA25DU14* 10 14
7.5 13.5 T2H160 MA 20 180 A30 TA450SU60 4 10 15
11 19 T2H160 MA 32 240 A30 TA450SU80 3 18 27
15 26 T2H160 MA 32 336 A50 TA450SU60 2 20 30
18.5 32 T2H160 MA 52 469 A50 TA450SU80 2 28 40
22 38 T2H160 MA 52 547 A50 TA450SU80 2 28 40
30 52 T2H160 MA 80 720 A63 TA450SU60 40 60
37 63 T2H160 MA 80 840 A95 TA450SU80 55 80
45 75 T2H160 MA 100 1050 A110 TA450SU105 70 105
55 90 T4H250 PR221-I In160 1200 A145 E200DU200 60 200
75 120 T4H250 PR221-I In250 1750 A185 E200DU200 60 200
90 147 T4H250 PR221-I In250 2000 A210 E320DU320 100 320
110 177 T4H250 PR221-I In250 2500 A260 E320DU320 100 320
132 212 T4H320 PR221-I In320 3200 A300 E320DU320 100 320

1SDC010021F0201
160 260 T5H400 PR221-I In400 3600 AF400 E500DU500 150 500
200 320 T5H630 PR221-I In630 4410 AF460 E500DU500 150 500
250 410 T5H630 PR221-I In630 5355 AF580 E500DU500*** 150 500
290 448 S6H630 PR211-I In630 7560 AF750 E500DU500*** 150 500
315 500 S6H800 PR211-I In800 8000 AF 750 E800DU800 250 800
355 549 S6H800 PR211-I In800 9600 AF 750 E800DU800 250 800
* Provide a by-pass contactor of the same size during motor start-up
** For type E releases choose tripping class 30
*** Connecting kit not available. To use the connecting kit, replacement with release E800DU800 is necessary
MA: magnetic only adjustable release
MF: fixed magnetic only release

ABB SACE - Electrical devices 125

 3.3 Protection and switching of motors

3 Protection of electrical equipment

Table 8: 440 V 50 kA Y/ Normal Type 2
(Tmax, Isomax Contactor Thermal release)

MOTOR MCCB Contactor Thermal Overload Relay

I3 LINE DELTA STAR
Pe [kW] Ir [A] Type [A] Type Type Type Type [A]
18.5 32 T2H160 MA52 392 A 50 A 50 A 16 TA75DU25 18-25
22 38 T2H160 MA52 469 A 50 A 50 A 26 TA75DU25 18-25
30 52 T2H160 MA80 720 A 63 A 63 A 26 TA75DU42 29-42
37 63 T2H160 MA80 840 A 75 A 75 A 30 TA75DU42 29-42
45 75 T2H160 MA80 960 A 75 A 75 A30 TA75DU52 36-52
55 90 T2H160 MA100 1150 A 75 A 75 A40 TA75DU63 45 - 63
75 120 T4H250 PR221-I In250 1625 A95 A95 A75 TA80DU80 60-80
90 147 T4H250 PR221-I In250 1875 A95 A95 A75 TA110DU110 80-110
110 177 T4H250 PR221-I In250 2250 A145 A145 A95 E200DU200 60-200

1SDC010025F0201
132 212 T4H320 PR221-I In320 2720 A145 A145 A110 E200DU200 60-200
160 260 T5H400 PR221-I In400 3200 A185 A185 A145 E200DU200 60-200
200 320 T5H630 PR221-I In630 4095 A210 A210 A185 E320DU320 100-320
250 410 T5H630 PR221-I In630 5040 A260 A260 A210 E320DU320 100-320
MA : Magnetic only adjustable release

126 ABB SACE - Electrical devices

 3.3 Protection and switching of motors

3 Protection of electrical equipment

Table 9: 500 V 50 kA DOL Normal Type 2
(Tmax, Isomax Contactor Thermal release)

Motor MCCB Contactor Thermal Overload Relay

Type Type Type Current
setting
Pe Ir I3 min. max.
[kW] [A] [A] [A] [A]
0.37 0.88 T2L160 MF 1 13 A9 TA25DU1.0 0.63 1
0.55 1.2 T2L160 MF 1.6 21 A9 TA25DU1.4 1 1.4
0.75 1.5 T2L160 MF 1.6 21 A9 TA25DU1.8 1.3 1.8
1.1 2.2 T2L160 MF 2.5 33 A9 TA25DU3.1 2.2 3.1
1.5 2.8 T2L160 MF 3.2 42 A16 TA25DU4 2.8 4
2.2 4 T2L160 MF 4 52 A26 TA25DU5 3.5 5
3 5.2 T2L160 MF 6.5 84 A26 TA25DU6.5 4.5 6.5
4 6.9 T2L160 MF 8.5 110 A30 TA25DU8.5 6 8.5
5.5 9.1 T2L160 MF 11 145 A30 TA25DU11 7.5 11
7.5 12.2 T2L160 MF 12.5 163 A30 TA25DU14 10 14
11 17.5 T2L160 MA 20 240 A30 TA25DU19 13 19
15 23 T2L160 MA 32 336 A50 TA75DU25 18 25
18.5 29 T2L160 MA 52 392 A50 TA75DU32 22 32
22 34 T2L160 MA 52 469 A50 TA75DU42 29 42
30 45 T2L160 MA 52 624 A63 TA75DU52 36 52
37 56 T2L160 MA 80 840 A75 TA75DU63 45 63
45 67 T2L160 MA 80 960 A95 TA80DU80 60 80
55 82 T2L160 MA 100 1200 A110 TA110DU90 65 90
75 110 T4H250 PR221-I In160 1440 A145 E200DU200 60 200
90 132 T4H250 PR221-I In250 1875 A145 E200DU200 60 200
110 158 T4H250 PR221-I In250 2250 A185 E200DU200 60 200
132 192 T4H320 PR221-I In320 2720 A210 E320DU320 100 320
160 230 T5H400 PR221-I In400 3600 A260 E320DU320 100 320
1SDC010026F0201

200 279 T5H400 PR221-I In400 4000 A300 E320DU320 100 320
250 335 T5H630 PR221-I In630 4725 AF 400 E 500DU500 150 500
290 394 T5H630 PR221-I In630 5040 AF 460 E 500DU500 150 500
315 440 S6L630 PR211-I In630 7560 AF 580 E 500DU500* 150 500
355 483 S6L630 PR211-I In630 7560 AF 580 E 800DU800 250 800

* Connection kit not available

MA: magnetic only adjustable release
MF: fixed magnetic only release

ABB SACE - Electrical devices 127

 3.3 Protection and switching of motors

3 Protection of electrical equipment

Table 10: 500 V 50 kA DOL Heavy duty Type 2
(Tmax, Isomax Contactor Thermal release)

Motor MCCB Contactor Thermal Overload Relay

Type Setting of Type Type** No. of Setting
the turns of range
Pe Ir magnetic the CT
release primary min. max.
[kW] [A] [A]
coil [A] [A]
0.37 0.88 T2L160 MF 1 13 A9 TA25DU1.0* 0.63 1
0.55 1.2 T2L160 MF 1.6 21 A9 TA25DU1.4* 1 1.4
0.75 1.5 T2L160 MF 1.6 21 A9 TA25DU1.8* 1.3 1.8
1.1 2.2 T2L160 MF 2.5 33 A9 TA25DU3.1* 2.2 3.1
1.5 2.8 T2L160 MF 3.2 42 A16 TA25DU4* 2.8 4
2.2 4 T2L160 MF 4 52 A26 TA25DU5* 3.5 5
3 5.2 T2L160 MF 6.5 84 A26 TA25DU6.5* 4.5 6.5
4 6.9 T2L160 MF 8.5 110 A30 TA25DU8.5* 6 8.5
5.5 9.1 T2L160 MF 11 145 A30 TA25DU11* 7.5 11
7.5 12.2 T2L160 MF 12.5 163 A30 TA450SU60 4 10 15
11 17.5 T2L160 MA 20 240 A30 TA450SU60 3 13 20
15 23 T2L160 MA 32 336 A50 TA450SU60 2 20 30
18.5 29 T2L160 MA 52 392 A50 TA450SU80 2 27.5 40
22 34 T2L160 MA 52 469 A50 TA450SU80 2 27.5 40
30 45 T2L160 MA 52 624 A63 TA450SU60 40 60
37 56 T2L160 MA 80 840 A75 TA450SU60 40 60
45 67 T2L160 MA 80 960 A95 TA450SU80 55 80
55 82 T2L160 MA 100 1200 A145 TA450SU105 70 105
75 110 T4H250 PR221-I In160 1440 A145 E200DU200 60 200
90 132 T4H250 PR221-I In250 1875 A185 E200DU200 60 200
110 158 T4H250 PR221-I In250 2123 A210 E320DU320 100 320
132 192 T4H320 PR221-I In320 2720 A260 E320DU320 100 320

1SDC010021F0201
160 230 T5H400 PR221-I In400 3200 A300 E320DU320 100 320
200 279 T5H400 PR221-I In400 3600 AF400 E500DU500 150 500
250 335 T5H630 PR221-I In630 4725 AF460 E500DU500 150 500
290 394 T5H630 PR221-I In630 5040 AF580 E500DU500*** 150 500
315 440 S6L630 PR211-I In630 7560 AF750 E500DU500*** 150 500
355 483 S6L630 PR211-I In630 7560 AF750 E500DU500 150 500
* Provide a by-pass contactor of the same size during motor start-up
** For type E releases choose tripping class 30
*** Connecting kit not available. To use the connecting kit, replacement with release E800DU800 is necessary
MA: magnetic only adjustable release
MF: fixed magnetic only release

128 ABB SACE - Electrical devices

 3.3 Protection and switching of motors

3 Protection of electrical equipment

Table 11: 500 V 50 kA Y/ Normal Type 2
(Tmax, Isomax Contactor Thermal release)

MOTOR MCCB Contactor Thermal Overload Relay

I3 LINE DELTA STAR
Pe [kW] Ir [A] Type [A] Type Type Type Type [A]
22 34 T2L160 MA52 430 A 50 A 50 A 16 TA75DU25 18-25
30 45 T2L160 MA52 547 A 63 A 63 A 26 TA75DU32 22-32
37 56 T2L160 MA80 720 A 75 A 75 A 30 TA75DU42 29-42
45 67 T2L160 MA80 840 A 75 A 75 A30 TA75DU52 36 - 52
55 82 T2L160 MA100 1050 A 75 A 75 A30 TA75DU52 36 - 52
75 110 T4H250 PR221-I In250 1375 A95 A95 A50 TA80DU80 60-80
90 132 T4H250 PR221-I In250 1750 A95 A95 A75 TA110DU90 65-90
110 158 T4H250 PR221-I In250 2000 A110 A110 A95 TA110DU110 80-110
132 192 T4H320 PR221-I In320 2560 A145 A145 A95 E200DU200 60-200

1SDC010027F0201
160 230 T4H320 PR221-I In320 2880 A145 A145 A110 E200DU200 60-200
200 279 T5H400 PR221-I In400 3400 A210 A210 A145 E320DU320 100-320
250 335 T5H630 PR221-I In630 4410 A210 A210 A185 E320DU320 100-320
290 394 T5H630 PR221-I In630 5040 A260 A260 A210 E320DU320 100-320

MA: magnetic only adjustable release

ABB SACE - Electrical devices 129

 3.3 Protection and switching of motors

3 Protection of electrical equipment

Example:
For a Y/ Normal starting Type 2, of a three phase asynchronous squirrel-cage
motor with the following data:
rated voltage Ur = 400 V
short-circuit current Ik = 50 kA
rated motor power Pe = 200 kW
from Table 5, on the relevant row, the following information can be found:

Ir (rated current): 349 A;

short-circuit protection device: circuit breaker T5S630 PR221-I In630;
magnetic trip threshold: I3 = 4410 A;
line contactor: A210;
delta contactor: A210;
star contactor: A185;
thermal release E320DU320, setting range 100-320 A
(to be set at I r = 202 A ).
3

130 ABB SACE - Electrical devices

 3 Protection of electrical equipment

3.4 Protection and switching of

transformers
General aspects
Transformers are used to achieve a change in the supply voltage, for both
medium and low voltage supplies.
The choice of the protection devices must take into account transient insertion
phenomena, during which the current may reach values higher than the rated
full load current; the phenomenon decays in a few seconds.
The curve which represents these transient phenomena in the time-current
diagram, termed inrush current I0, depends on the size of the transformer
and can be evaluated with the following formula (the short-circuit power of the
network is assumed equal to infinity) K I e ( t / )
r1
I0 =
where: 2
K ratio between the maximum peak inrush current value ( I0 ) and the rated
current of the transformer (I1r): (K= I0 / I1r);
time constant of the inrush current;
I1r rated current of the primary;
t time.

The table below shows the indicative values for t and K parameters referred to
rated power Sr for oil transformers.

Sr [kVA] 50 100 160 250 400 630 1000 1600 2000

K = Io/I1r 15 14 12 12 12 11 10 9 8
[s] 0.10 0.15 0.20 0.22 0.25 0.30 0.35 0.40 0.45

Further to the above consideration, the follwing diagram shows the inrush
current curve for a 20/0.4kV of 400kVA transformer. This transformer has an
inrush current during the very first moments equal to about 8 times the rated
current; this transient phenomenon stops after a few tenths of a second.
10

[s]

10-1
1SDC010022F0001

10-2
10-3 10-2 10-1 1
[kA]

ABB SACE - Electrical devices 131

 3.4 Protection and switching of transformers

3 Protection of electrical equipment

The transformer protection devices must also guarantee that the transformer
cannot operate above the point of maximum thermal overload under short-
circuit conditions; this point is defined on the time-current diagram by the value
of short-circuit current which can pass through the transformer and by a time
equal to 2 s, as stated by Standard IEC 60076-5. The short-circuit current (Ik)
flowing for a fault with low impedance at the LV terminals of the transformer is
calculated by using the following formula:

Ur
Ik = [A] (1)
3 ( ZNet + Zt )
where:
Ur is the rated voltage of the transformer [V];
ZNet is the short-circuit impedance of the network [];
Zt is the short-circuit impedance of the transformer; from the rated power of
the transformer (Sr [VA]) and the percentage short-circuit voltage (uk%) is
equal to:

uk % U r2
Zt = [] (2)
100 Sr

Considering the upstream short-circuit power of the network to be infinite

(ZNet=0), formula (1) becomes:

Ur Ur 100 Sr
Ik = = = [A] (3)
3 ( Zt ) uk % U r2 3 uk % Ur

3

100 Sr

The diagram below shows the inrush current curve for a 20/0.4 kV of 400 kVA
transformer (uk% = 4 %) and the point referred to the thermal ability to with the
short-circuit current (Ik; 2 sec.).

1s

10-1s
1SDC010023F0001

10-2s

1kA 10kA

132 ABB SACE - Electrical devices

 3.4 Protection and switching of transformers

3 Protection of electrical equipment

In summary: for the correct protection of the transformer and to avoid unwanted
trips, the trip curve of the protection device must be above the inrush current
curve and below the overload point.
The diagram below shows a possible position of the time-current curve of an
upstream protection device of a 690/400 V, 250 kVA transformer with uk% = 4 %.

10 4 s

10 3 s
T4N250 PR221 In=250 A
2
10 s

10 1 s

250 kVA Trafo

1s

10-1s

1SDC010024F0001
10-2s

10-1 kA 1kA 10kA

Criteria for the selection of protection devices

For the protection at the LV side of MV/LV transformers, the selection of a
circuit breaker shall take into account:
the rated current at LV side of the protected transformer (this value is the
reference value for the rated current of the circuit breaker and the setting of
the protections);
the maximum short-circuit current at the point of installation (this value
determines the minimum breaking capacity (Icu/Ics) of the protection device).

MV/LV unit with single transformer

The rated current at the LV side of the transformer (Ir) is determined by the
following formula:
1000 Sr
Ir = [A] (4)
3 U r 20

where:
Sr is the rated power of the transformer [kVA];
Ur20 is the rated LV no-load voltage of the transformer [V].

ABB SACE - Electrical devices 133

 3.4 Protection and switching of transformers

3 Protection of electrical equipment

The full voltage three-phase short-circuit current (Ik), at the LV terminals of the
transformer, can be expressed as (assuming that the short-circuit power of the
network is infinite):
100 I r
Ik = [A] (5)
uk %
where:
uk% is the short-circuit voltage of the transformer, in %.

The protection circuit-breaker must have:

In I r;
Icu (Ics) Ik.

If the short-circuit power of the upstream network is not infinite and cable or
busbar connections are present, it is possible to obtain a more precise value
for Ik by using formula (1), where ZNet is the sum of the impedance of the
network and of the impedance of the connection.

MV/LV substation with more than one transformer in parallel

For the calculation of the rated current of the transformer, the above applies
(formula 4).

The breaking capacity of each protection circuit-breaker on the LV side shall be

higher than the short-circuit current equivalent to the short-circuit current of
each equal transformer multiplied by the number of them minus one.
As can be seen from the diagram below, in the case of a fault downstream of a
transformer circuit-breaker (circuit-breaker A), the short-circuit current that flows
through the circuit-breaker is equal to the contribution of a single transformer.
In the case of a fault upstream of the same circuit-breaker, the short-circuit
current that flows is equal to the contribution of the other two transformers in
parallel.

134 ABB SACE - Electrical devices

 3.4 Protection and switching of transformers

3 Protection of electrical equipment

For a correct dimensioning, a circuit-breaker with a breaking capacity higher
than twice the short-circuit current of one of the transformers must be chosen
(assuming that all the transformers are equal and the loads are passive).

The circuit-breakers positioned on the outgoing feeders (circuit-breakers B)

shall have a breaking capacity higher than the sum of the short-circuit currents
of the three transformers, according to the hypothesis that the upstream network
short-circuit power is 750 MVA and the loads are passive.

Ik1 Ik2 Ik3

Ik2 + Ik3 A

1SDC010025F0001
Ik = Ik1 + Ik2 + Ik3

ABB SACE - Electrical devices 135

 3.4 Protection and switching of transformers

3 Protection of electrical equipment

Selection of the circuit-breaker
The following tables show some possible choices of ABB SACE circuit-breakers,
according to the characteristics of the transformer to be protected.

Table 1: Protection and switching of 230 V transformers

Transformer Circuit Breaker "A" (LV side) Circuit B

Trafo
Sr uk Trafo Ir Busbar Ib ABB SACE Release Busbar Ik Fee
Feeder Ik
Circuit Breaker
[kVA] % [A] [A] [kA] size setting [kA] 32 A 63 A 125 A 160 A 250 A 400 A 630 A
1 x 63 158 158 3.9 T1B160 In=160 1 3.9 S250/S260 T1B160
4
2 x 63 158 316 3.9 T1B160 In=160 1 7.9 S250/S260 T1B160 T3N250
1 x 100 251 251 6.3 T4N320 In=320 0.9 6.3 S250/S260 T1B160
4
2 x 100 251 502 6.2 T4N320 In=320 0.9 12.5 S250/S260 T1B160 T3N250 T5N400
1 x 125 314 314 7.8 T5N400 In=400 0.9 7.8 S250/S260 T1B160 T3N250
4
2 x 125 314 628 7.8 T5N400 In=400 0.9 15.6 S250/S260 T1B160 T3N250 T5N400
1 x 160 402 402 10.0 T5N630 In=630 0.7 10.0 S250/S260 T1B160 T3N250
4
2 x 160 402 803 9.9 T5N630 In=630 0.7 19.9 T1B160 T3N250 T5N400 T5N63
1 x 200 502 502 12.5 T5N630 In=630 0.9 12.5 S250/S260 T1B160 T3N250 T5N400
4
2 x 200 502 1004 12.4 T5N630 In=630 0.9 24.8 T1B160 T3N250 T5N400 T5N63
1 x 250 628 628 15.6 T5N630 In=630 1 15.6 S250/S260 T1B160 T3N250 T5N400
4
2 x 250 628 1255 15.4 T5N630 In=630 1 30.9 T1C160 T3N250 T5N400 T5N63
1 x 315 791 791 19.6 S6N800 In=800 1 19.6 T1B160 T3N250 T5N400 T5N63
4
2 x 315 791 1581 19.4 S6N800 In=800 1 38.7 T1C160 T3N250 T5N400 T5N63
1 x 400 1004 1004 24.8 S7S1250/E1B1250 In=1250 0.9 24.8 T1B160 T3N250 T5N400 T5N63
4
2 x 400 1004 2008 24.5 S7S1250/E1B1250 In=1250 0.9 48.9 T1N160 T3N250 T5N400 T5N63
1 x 500 1255 1255 30.9 S7S1600/E2B1600 In=1600 0.9 30.9 T1C160 T3N250 T5N400 T5N63
4
2 x 500 1255 2510 30.4 S7S1600/E2B1600 In=1600 0.9 60.7 T2N160 T3S250 T5N400 T5N63
1 x 630 1581 1581 38.7 S7S1600/E2B1600 In=1600 1 38.7 T1C160 T3N250 T5N400 T5N63
2 x 630 4 1581 3163 37.9 S7S1600/E2B1600 In=1600 1 75.9 T2S160 T3S250 T5S400 T5S630
3 x 630 1581 4744 74.4 S7S1600/E3S1600 In=1600 1 111.6 T2L160 T4L250 T5L400 T5L630
1 x 800 2008 2008 39.3 E3N2500 In=2500 0.9 39.3 T1C160 T3N250 T5N400 T5N63
2 x 800 5 2008 4016 38.5 E3N2500 In=2500 0.9 77.0 T2S160 T3S250 T5S400 T5S630
3 x 800 2008 6025 75.5 E3H2500 In=2500 0.9 113.2 T2L160 T4L250 T5L400 T5L630
1 x 1000 2510 2510 48.9 E3N3200 In=3200 0.8 48.9 T1N160 T3N250 T5N400 T5N63
2 x 1000 5 2510 5020 47.7 E3N3200 In=3200 0.8 95.3 T2H160 T4H250 T5H400 T5H63
3 x 1000 2510 7531 93.0 E3H3200 In=3200 0.8 139.5 T4L250 T4L250 T5L400 T5L630
1 x 1250 3138 3138 60.7 E3N3200 In=3200 1 60.7 T2N160 T3S250 T5N400 T5N63
2 x 1250 5 3138 6276 58.8 E3N3200 In=3200 1 117.7 T2L160 T4L250 T5L400 T5L630
3 x 1250 3138 9413 114.1 S8V3200/E6V3200 In=3200 1 171.2 T4L250 T4L250 T5L400 T5L630

136 ABB SACE - Electrical devices

 3.4 Protection and switching of transformers

3 Protection of electrical equipment

Circuit Breaker "B" (Feeder Circuit Breaker)

Feeder Circuit Breaker type and rated current
2 A 63 A 125 A 160 A 250 A 400 A 630 A 800 A 1250 A 1600 A 2000 A 2500 A 3200 A 4000 A
250/S260 T1B160
250/S260 T1B160 T3N250
250/S260 T1B160
250/S260 T1B160 T3N250 T5N400
250/S260 T1B160 T3N250
250/S260 T1B160 T3N250 T5N400
250/S260 T1B160 T3N250
T1B160 T3N250 T5N400 T5N630
250/S260 T1B160 T3N250 T5N400
T1B160 T3N250 T5N400 T5N630
250/S260 T1B160 T3N250 T5N400
T1C160 T3N250 T5N400 T5N630 S6N800
T1B160 T3N250 T5N400 T5N630
T1C160 T3N250 T5N400 T5N630 S6N800 S7S1250
T1B160 T3N250 T5N400 T5N630 S6N800
T1N160 T3N250 T5N400 T5N630 S6N800 S7S1250/E1N1250 S7S1600/E2N1600
T1C160 T3N250 T5N400 T5N630 S6N800
T2N160 T3S250 T5N400 T5N630 S6N800 S7S1250/E2N1250 S7S1600/E2N1600 E2N2000
T1C160 T3N250 T5N400 T5N630 S6N800 S7S1250/E1N1250
T2S160 T3S250 T5S400 T5S630 S6S800 S7S1250/E2L1250 S7S1600/E2L1600 E3H2000 E3H2500
T2L160 T4L250 T5L400 T5L630 S6L800 S7L1250/E2L1250 S7L1600/E2L1600 E3L2000 E3L2500 E6V3200
T1C160 T3N250 T5N400 T5N630 S6N800 S7S1250/E1B1250 S7S1600/E2B1600
T2S160 T3S250 T5S400 T5S630 S6S800 S7S1250/E2L1250 S7S1600/E2L1600 E3H2000 E3H2500 E3H3200
T2L160 T4L250 T5L400 T5L630 S6L800 S7L1250/E2L1250 S7L1600/E2L1600 E3L2000 E3L2500 E6V3200 E6V4000
T1N160 T3N250 T5N400 T5N630 S6N800 S7S1250/E1N1250 S7S1600/E2N1600 E2N2000
1SDC010035F0201

T2H160 T4H250 T5H400 T5H630 S6H800 S7H1250/E2L1250 S7H1600/E2L1600 E3H2000 E3H2500 E3H3200 E4H4000
T4L250 T4L250 T5L400 T5L630 S6L800 S7L1250 S7L1600 E6V3200 E6V3200 E6V3200 E6V4000
T2N160 T3S250 T5N400 T5N630 S6N800 S7S1250/E2N1250 S7S1600/E2N1600 E2N2000 E3N2500
T2L160 T4L250 T5L400 T5L630 S6L800 S7L1250/E2L1250 S7L1600/E2L1600 E3L2000 E3L2500 E6V3200 E6V4000
T4L250 T4L250 T5L400 T5L630 S6L800 S7L1250 S7L1600

ABB SACE - Electrical devices 137

 3.4 Protection and switching of transformers

3 Protection of electrical equipment

Table 2: Protection and switching of 400 V transformers

Transformer Circuit Breaker "A" (LV side) Circuit Break

Trafo
Sr uk Trafo I r Busbar Ib ABB SACE Release Busbar Ik Feeder C
Feeder Ik
Circuit Breaker
[kVA] % [A] [A] [kA] size setting [kA] 32 A 63 A 125 A 160 A 250 A 400 A 630 A 80
1 x 63 91 91 2.2 T1B/T2N160 In=100 0.96 2.2 S250/S260
4
2 x 63 91 182 2.2 T1B/T2N160 In=100 0.96 4.4 S250/S260 T1B160
1 x 100 144 144 3.6 T1B/T2N160 In=160 0.92 3.6 S250/S260 T1B160
4
2 x 100 144 288 3.6 T1B/T2N160 In=160 0.92 7.2 S250/S260 T1B160
1 x 125 180 180 4.5 T3N250 In=250 0.95/0.8 4.5 S250/S260 T1B160
4
2 x 125 180 360 4.4 T3N250 In=250 0.95/0.8 8.8 S250/S260 T1B160
1 x 160 231 231 5.7 T3N250 In=250 0.95/0.95 5.7 S250/S260 T1B160
4
2 x 160 231 462 5.7 T3N250 In=250 0.95/0.95 11.4 T1B160 T3N250
1 x 200 289 289 7.2 T4N320 In=320 0.95 7.2 S250/S260 T1B160 T3N250
4
2 x 200 289 578 7.1 T4N320 In=320 0.95 14.2 T1B160 T3N250 T5N400
1 x 250 361 361 8.9 T5N400 In=400 0.95 8.9 S250/S260 T1B160 T3N250
4
2 x 250 361 722 8.8 T5N400 In=400 0.95 17.6 T1C160 T3N250 T5N400
1 x 315 455 455 11.2 T5N630 In=630 0.8 11.2 T1B160 T3N250 T5N400
4
2 x 315 455 910 11.1 T5N630 In=630 0.8 22.2 T1C160 T3N250 T5N400 T5N630
1 x 400 577 577 14.2 T5N630/S6N800 In=630/800 0.95/0.8 14.2 T1B160 T3N250 T5N400
4
2 x 400 577 1154 14 T5N630/S6N800 In=630/800 0.95/0.8 28 T1N160 T3N250 T5N400 T5N630
1 x 500 722 722 17.7 S6N800/S7S1250 In=800/1000 0.95/0.8 17.7 T1C160 T3N250 T5N400 T5N630
4
2 x 500 722 1444 17.5 S6N800/S7S1250 In=800/1000 0.95/0.8 35.9 T1N160 T3N250 T5N400 T5N630 S6N
1 x 630 909 909 22.3 S7S1250/E1B1250 In=1000 0.95 22.3 T1C160 T3N250 T5N400 T5N630 S6N800
2 x 630 4 909 1818 21.8 S7S1250/E1B1250 In=1000 0.95 43.6 T2S160 T3S250 T5S400 T5S630 S6S800
3 x 630 909 2727 42.8 S7S1250/E1N1250 In=1000 0.95 64.2 T2H160 T4H250 T5H400 T5H630 S6L800/
1 x 800 1155 1155 22.6 S7S1250/E1B1250 In=1250 0.95 22.6 T1C160 T3N250 T5N400 T5N630 S6N800
2 x 800 5 1155 2310 22.1 S7S1250/E1B1250 In=1250 0.95 44.3 T2S160 T3S250 T5S400 T5S630 S6S800
3 x 800 1155 3465 43.4 S7S1250/E1N1250 In=1250 0.95 65 T2H160 T4H250 T5H400 T5H630 S6L800/
1 x 1000 1443 1443 28.1 S7S1600/E2B1600 In=1600 0.95 28.1 T1N160 T3N250 T5N400 T5N630 S6N800
2 x 1000 5 1443 2886 27.4 S7S1600/E2B1600 In=1600 0.95 54.8 T2H160 T4H250 T5H400 T5H400 S6H800/
3 x 1000 1443 4329 53.5 S7H1600/E2N1600 In=1600 0.95 80.2 T2L160 T4L250 T5L400 T5L630 S6L800/
1 x 1250 1804 1804 34.9 E2B2000 In=2000 0.95 34.9 T1N160 T3N250 T5N400 T5N630 S6N800
2 x 1250 5 1804 3608 33.8 E2B2000 In=2000 0.95 67.7 T2H160 T4H250 T5H400 T5H630 S6L800/
3 x 1250 1804 5412 65.6 E3S2000 In=2000 0.95 98.4 T4L250 T4L250 T5L400 T5L630 S6L800/
1 x 1600 2309 2309 35.7 E3N2500 In=2500 0.95 35.7 T2N160 T3N250 T5N400 T5N630 S6N800
2 x 1600 6.25 2309 4618 34.6 E3N2500 In=2500 0.95 69.2 T2H160 T4H250 T5H400 T5H630 S6L800/
3 x 1600 2309 6927 67 E3S2000 In=2500 0.95 100.6 T4L250 T4L250 T5L400 T5L630
1 x 2000 2887 2887 44.3 E3N3200 In=3200 0.95 44.3 T2S160 T3S250 T5S400 T5S630 S6S800
2 x 2000 6.25 2887 5774 42.6 E3N3200 In=3200 0.95 85.1 T4L250 T4L250 T5L400 T5L630 S6L800/
3 x 2000 2887 8661 81.9 E3H3200 In=3200 0.95 122.8 T4L250 T4V250 T5V400 T5V630
1 x 2500 6.25 3608 3608 54.8 E4S4000 In=4000 1 54.8 T2H160 T4H250 T5H400 T5H630 S6H800/
1 x 3125 6.25 4510 4510 67.7 E6H5000 In=5000 1 67.7 T2H160 T4H250 T5H400 T5H630 S6L800/

138 ABB SACE - Electrical devices

 3.4 Protection and switching of transformers

3 Protection of electrical equipment

Circuit Breaker "B" (Feeder Circuit Breaker)

Feeder Circuit Breaker type and rated current
A 125 A 160 A 250 A 400 A 630 A 800 A 1250 A 1600 A 2000 A 2500 A 3200 A 4000 A
0
0 T1B160
0 T1B160
0 T1B160
0 T1B160
0 T1B160
0 T1B160
T1B160 T3N250
0 T1B160 T3N250
T1B160 T3N250 T5N400
0 T1B160 T3N250
T1C160 T3N250 T5N400
T1B160 T3N250 T5N400
T1C160 T3N250 T5N400 T5N630
T1B160 T3N250 T5N400
T1N160 T3N250 T5N400 T5N630
T1C160 T3N250 T5N400 T5N630
T1N160 T3N250 T5N400 T5N630 S6N800
T1C160 T3N250 T5N400 T5N630 S6N800/E1B800
T2S160 T3S250 T5S400 T5S630 S6S800/E1N800 S7S1250/E1N1250
T2H160 T4H250 T5H400 T5H630 S6L800/E2N1250 S7L1250/E2N1250 S7L1600/E2N1600
T1C160 T3N250 T5N400 T5N630 S6N800/E1B800
T2S160 T3S250 T5S400 T5S630 S6S800/E1N800 S7S1250/E1N1250 S7S1600/E2N1600
T2H160 T4H250 T5H400 T5H630 S6L800/E2N1250 S7L1250/E2N1250 S7L1600/E2N1600 E2N2000 E3N2500
T1N160 T3N250 T5N400 T5N630 S6N800/E1B800 S7S1250/E1B1250
T2H160 T4H250 T5H400 T5H400 S6H800/E2N1250 S7H1250/E2N1250 S7H1600/E2N1600 E2N2000
T2L160 T4L250 T5L400 T5L630 S6L800/E3H1250 S7L1250/E3H1250 S7L1600/E3H1600 E3H2000 E3H2500 E3H3200
T1N160 T3N250 T5N400 T5N630 S6N800/E1B800 S7S1250/E1B1250 S7S1600/E2B1600
T2H160 T4H250 T5H400 T5H630 S6L800/E3H1250 S7L1250/E3S1250 S7L1600/E3S1600 E3S2000 E3S2500 E3S3200
T4L250 T4L250 T5L400 T5L630 S6L800/E3H1250 S7L1250/E3H1250 S7L1600/E3H1600 E3H2000 E3H2500 E3H3200 E4H4000
T2N160 T3N250 T5N400 T5N630 S6N800/E1B800 S7S1250/E1B1250 S7S1600/E2B1600
T2H160 T4H250 T5H400 T5H630 S6L800/E3S1250 S7L1250/E3S1250 S7L1600/E3S1600 E3S2000 E3S2500 E3S3200 E4S4000
1SDC010036F0201

T4L250 T4L250 T5L400 T5L630 S8V2000/E2L1250 S8V2000/E2L1600 E3L2000 E3L2500 E6V3200 E6V4000
T2S160 T3S250 T5S400 T5S630 S6S800/E1N800 S7S1250/E1N1250 S7S1600/E2N1600 E2N2000
T4L250 T4L250 T5L400 T5L630 S6L800/E3H1250 S7L1250/E3H1250 S7L1600/E3H1600 E3H2000 E3H2500 E3H3200 E4H4000
T4L250 T4V250 T5V400 T5V630 E2L1250 E2L1600 E3L2000 E3L2500 E6V3200 E6V4000
T2H160 T4H250 T5H400 T5H630 S6H800/E2N1250 S7H1250/E2N1250 S7H1600/E2N1600 E2N2000 E3N2500 E3N3200
T2H160 T4H250 T5H400 T5H630 S6L800/E3S1250 S7L1250/E3S1250 S7L1600/E3S1600 E3S2000 E3S2500 E3S3200 E4S4000

ABB SACE - Electrical devices 139

 3.4 Protection and switching of transformers

3 Protection of electrical equipment

Table 3: Protection and switching of 440 V transformers

Transformer Circuit Breaker "A" (LV side) Circuit Breake

Trafo
Sr uk Trafo I r Busbar Ib ABB SACE Release Busbar Ik Feeder C
Feeder Ik
Circuit Breaker
[kVA] % [A] [A] [kA] size setting [kA] 32 A 63 A 125 A 160 A 250 A 400 A 630 A 800
1 x 63 83 83 2.1 T1B/T2N160 In=100 0.9/0.88 2.1 S250/S260
4
2 x 63 83 165 2.1 T1B/T2N160 In=100 0.9/0.88 4.1 S250/S260 T1B160
1 x 100 131 131 3.3 T1B/T2N160 In=160 0.85/0.88 3.3 S250/S260
4
2 x 100 131 262 3.3 T1B/T2N160 In=160 0.85/0.88 6.5 T1B160
1 x 125 164 164 4.1 T3N/T4N250 In=250 0.9/0.7 4.1 S250/S260 T1B160
4
2 x 125 164 328 4.1 T3N/T4N250 In=250 0.9/0.7 8.1 T1B160 T3N250
1 x 160 210 210 5.2 T3N/T4N250 In=250 0.9 5.2 S250/S260 T1B160
4
2 x 160 210 420 5.2 T3N/T4N250 In=250 0.9 10.4 T1C160 T3N250
1 x 200 262 262 6.5 T5N400 In=320 0.9 6.5 T1B160
4
2 x 200 262 525 6.5 T5N400 In=320 0.9 12.9 T1C160 T3N250 T5N400
1 x 250 328 328 8.1 T5N400 In=400 0.9 8.1 T1B160 T3N250
4
2 x 250 328 656 8.1 T5N400 In=400 0.9 16.1 T1N160 T3N250 T5N400
1 x 315 413 413 10.2 T5N630 In=630 0.7 10.2 T1C160 T3N250
4
2 x 315 413 827 10.1 T5N630 In=630 0.7 20.2 T1N160 T3N250 T5N400 T5N630
1 x 400 525 525 12.9 T5N630 In=630 0.9 12.9 T1C160 T3N250 T5N400
4
2 x 400 525 1050 12.8 T5N630 In=630 0.9 25.6 T2N160 T3S250 T5N400 T5N630
1 x 500 656 656 16.1 S6N800 In=800 0.9 16.1 T1N160 T3N250 T5N400
4
2 x 500 656 1312 15.9 S6N800 In=800 0.9 31.7 T2S160 T3S250 T5S400 T5S630 S6S8
1 x 630 827 827 20.2 S7S1250/E1B1250 In=1000 0.9 20.2 T1N160 T3N250 T5N400 T5N630
2 x 630 4 827 1653 19.8 S7S1250/E1B1250 In=1000 0.9 39.7 T2S160 T3S250 T5S400 T5S630 S6S800/E
3 x 630 827 2480 38.9 S7S1250/E1B1250 In=1000 0.9 58.3 T2L160 T4H250 T5H400 T5H630 S6L800/E
1 x 800 1050 1050 20.6 S7S1250/E1B1250 In=1250 0.9 20.6 T1N160 T3N250 T5N400 T5N630 S6N800/
2 x 800 5 1050 2099 20.1 S7S1250/E1B1250 In=1250 0.9 40.3 T2S160 T4H250 T5H400 T5H630 S6S800/E
3 x 800 1050 3149 39.5 S7S1250/E1B1250 In=1250 0.9 59.2 T2L160 T4H250 T5H400 T5H630 S6L800/E
1 x 1000 1312 1312 25.6 S7S1600/E2B1600 In=1600 0.9 25.6 T2N160 T3S250 T5N400 T5N630 S6N800/
2 x 1000 5 1312 2624 24.9 S7S1600/E2B1600 In=1600 0.9 49.8 T2H160 T4H250 T5H400 T5H630 S6L800/E
3 x 1000 1312 3936 48.6 S7H1600/E2N1600 In=1600 0.9 72.9 T2L160 T4L250 T5L400 T5L630 S6L800/E
1 x 1250 1640 1640 31.7 E2B2000 In=2000 0.9 31.7 T2S160 T3S250 T5S400 T5S630 S6S800/E
2 x 1250 5 1640 3280 30.8 E2B2000 In=2000 0.9 61.5 T2L160 T4H250 T5H400 T5H630 S6L800/E
3 x 1250 1640 4921 59.6 E2N2000 In=2000 0.9 89.5 T4L250 T4L250 T5L400 T5L630
1 x 1600 2099 2099 32.5 E2N2500 In=2500 0.9 32.5 T2S160 T3S250 T5S400 T5S630 S6S800/E
2 x 1600 6.25 2099 4199 31.4 E2N2500 In=2500 0.9 62.9 T2L160 T4H250 T5H400 T5H630 S6L800/E
3 x 1600 2099 6298 60.9 E2N2500 In=2500 0.9 91.4 T4L250 T4L250 T5L400 T5L630
1 x 2000 2624 2624 40.3 E3N3200 In=3200 0.9 40.3 T2S160 T4H250 T5H400 T5H630 S6S800/E
2 x 2000 6.25 2624 5249 38.7 E3N3200 In=3200 0.9 77.4 S4L160 T4L250 T5L400 T5L630 S6L800/E
3 x 2000 2624 7873 74.4 E3S3200 In=3200 0.9 111.7 T4V250 T4V250 T5V400 T5V630
1 x 2500 6.25 3280 3280 49.8 E4S4000 In=4000 0.9 49.8 T2H160 T4H250 T5H400 T5H630 S6L800/E
1 x 3125 6.25 4100 4100 61.5 E6H5000 In=5000 0.9 61.5 T2L160 T4H250 T5H400 T5H630 S6L800/E

140 ABB SACE - Electrical devices

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3 Protection of electrical equipment

Circuit Breaker "B" (Feeder Circuit Breaker)

Feeder Circuit Breaker type and rated current

63 A 125 A 160 A 250 A 400 A 630 A 800 A 1250 A 1600 A 2000 A 2500 A 3200 A 4000 A
260
260 T1B160
260
T1B160
260 T1B160
T1B160 T3N250
260 T1B160
T1C160 T3N250
T1B160
T1C160 T3N250 T5N400
T1B160 T3N250
T1N160 T3N250 T5N400
T1C160 T3N250
T1N160 T3N250 T5N400 T5N630
T1C160 T3N250 T5N400
T2N160 T3S250 T5N400 T5N630
T1N160 T3N250 T5N400
T2S160 T3S250 T5S400 T5S630 S6S800
T1N160 T3N250 T5N400 T5N630
T2S160 T3S250 T5S400 T5S630 S6S800/E1B800 S7S1250/E1B1250
T2L160 T4H250 T5H400 T5H630 S6L800/E2N1250 S7L1250/E2N1250 S7L1600/E2N1600 E2N2000
T1N160 T3N250 T5N400 T5N630 S6N800/E1B800
T2S160 T4H250 T5H400 T5H630 S6S800/E1B800 S7H1250/E1B1250 S7H1600/E2B1600
T2L160 T4H250 T5H400 T5H630 S6L800/E2N1250 S7L1250/E2N1250 S7L1600/E2N1600 E2N2000 E3N2500 E3N3200 E4S4000
T2N160 T3S250 T5N400 T5N630 S6N800/E1B800
T2H160 T4H250 T5H400 T5H630 S6L800/E2N1250 S7H1250/E1N1250 S7H1600/E2N1600 E2N2000
T2L160 T4L250 T5L400 T5L630 S6L800/E3S1250 S7L1250/E3S1250 S7L1600/E3S1600 E3S2000 E3S2500 E3S3200
T2S160 T3S250 T5S400 T5S630 S6S800/E1B800 S7S1250/E1B1250
T2L160 T4H250 T5H400 T5H630 S6L800/E2N1250 S7L1250/E2N1250 S7L1600/E2N1600 E2N2000 E3N2500
T4L250 T4L250 T5L400 T5L630 S8V2000/E2L1250 S8V2000/E2L1600 E3H2000 E3H2500 E3H3200 E4H4000
T2S160 T3S250 T5S400 T5S630 S6S800/E1B800 S7S1250/E1B1250 S7S1600/E2B1600
T2L160 T4H250 T5H400 T5H630 S6L800/E2N1250 S7L1250/E2N1250 S7L1600/E2N1600 E2N2000 E3N2500 E3N3200
1SDC010037F0201

T4L250 T4L250 T5L400 T5L630 S8V2000/E2L1250 S8V2000/E2L1600 E3H2000 E3H2500 E3H3200 E4H4000
T2S160 T4H250 T5H400 T5H630 S6S800/E1B800 S7H1250/E1N1250 S7H1600/E2B1600 E2B2000
S4L160 T4L250 T5L400 T5L630 S6L800/E3H1250 S7L1250/E3H1250 S7L1600/E3H1600 E3H2000 E3H2500 E3H3200 E4H4000
T4V250 T4V250 T5V400 T5V630 E6V3200 E6V4000
T2H160 T4H250 T5H400 T5H630 S6L800/E2N1250 S7H1250/E1N1250 S7H1600/E2N1600 E2N2000 E3N2500
T2L160 T4H250 T5H400 T5H630 S6L800/E2N1250 S7L1250/E2N1250 S7L1600/E2N1600 E2N2000 E3N2500 E3N3200

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Table 4: Protection and switching of 690 V transformers

Transformer Circuit Breaker "A" (LV side) Circuit Breaker "B"

Trafo
Sr uk Trafo I r Busbar Ib ABB SACE Release Busbar Ik Feeder Circuit
Feeder Ik
Circuit Breaker
[kVA] % [A] [A] [kA] size setting [kA] 32 A 63 A 125 A 160 A 250 A 400 A 630 A 800 A
1 x 63 53 53 1.3 T1B/T2N160 In=63 0.9/0.88 1.3 T1B160
4
2 x 63 53 105 1.3 T1B/T2N160 In=63 0.9/0.88 2.6 T1B160
1 x 100 84 84 2.1 T1B/T2N160 In=100 0.9/0.92 2.1 T1B160
4
2 x 100 84 167 2.1 T1B/T2N160 In=100 0.9/0.92 4.2 T1N160
1 x 125 105 105 2.6 T1B/T2N160 In=160 0.9/0.72 2.6 T1B160
4
2 x 125 105 209 2.6 T1B/T2N160 In=160 0.9/0.72 5.2 T1N160
1 x 160 134 134 3.3 T1C/T2N160 In=160 0.9/0.88 3.3 T1C160
4
2 x 160 134 268 3.3 T1C/T2N160 In=160 0.9/0.88 6.6 T2S160
1 x 200 167 167 4.2 T3N250/T4N250 In=250 0.9/0.8 4.2 T1N160
4
2 x 200 167 335 4.1 T3N250/T4N250 In=250 0.9/0.8 8.3 T2L160 T4N250
1 x 250 209 209 5.2 T3S250/T4N250 In=250 0.9 5.2 T1N160
4
2 x 250 209 418 5.1 T3S250/T4N250 In=250 0.9 10.3 T4N250 T4N250
1 x 315 264 264 6.5 T4N320 In=320 0.9 6.5 T2S160
4
2 x 315 264 527 6.5 T4N320 In=320 0.9 12.9 T4N250 T4N250 T5N400
1 x 400 335 335 8.3 T5N400 In=400 0.9 8.3 T2L160 T4N250
4
2 x 400 335 669 8.2 T5N400 In=400 0.9 16.3 T4N250 T4N250 T5N400
1 x 500 418 418 10.3 T5N630 In=630 0.7 10.3 T4N250 T4N250
4
2 x 500 418 837 10.1 T5N630 In=630 0.7 20.2 T4S250 T4S250 T5S400 T5S630
1 x 630 527 527 12.9 T5N630 In=630 0.9 12.9 T4N250 T4N250 T5N400
2 x 630 4 527 1054 12.6 T5N630 In=630 0.9 25.3 T4H250 T4H250 T5H400 T5H630
3 x 630 527 1581 24.8 T5S630 In=630 0.9 37.2 T4H250 T4H250 T5H400 T5H630
1 x 800 669 669 13.1 S6N800 In=800 0.9 13.1 T4N250 T4N250 T5N400
2 x 800 5 669 1339 12.8 S6N800 In=800 0.9 25.7 T4H250 T4H250 T5H400 T5H630 S6L800
3 x 800 669 2008 25.2 S6L800 In=800 0.9 37.7 T4H250 T4H250 T5H400 T5H630
1 x 1000 837 837 16.3 S7S1250/E1B1250 In=1000 0.9 16.3 T4N250 T4N250 T5N400 T5N630
2 x 1000 5 837 1673 15.9 S7S1250/E1B1250 In=1000 0.9 31.8 T4H250 T4H250 T5H400 T5H630 S7L1250/E1B
3 x 1000 837 2510 31.0 S7L1250/E1B1250 In=1000 0.9 46.5 T4L250 T4L250 T5L400 T5L630 S8V
1 x 1250 1046 1046 20.2 S7H1250/E1B1250 In=1250 0.9 20.2 T4S250 T4S250 T5S400 T5S630 S6S800/E1B
2 x 1250 5 1046 2092 19.6 S7S1250/E1B1250 In=1250 0.9 39.2 T4H250 T4H250 T5H400 T5H630 S8H
3 x 1250 1046 3138 38.0 E2B1250 In=1600 0.7 57.1 T4L250 T4L250 T5L400 T5L630
1 x 1600 1339 1339 20.7 E2B1600 In=1600 0.9 20.7 T4S250 T4S250 T5S400 T5S630 S6S800/E1B
2 x 1600 6.25 1339 2678 20.1 E2B1600 In=1600 0.9 40.1 T4L250 T4L250 T5L400 T5L630 S8V
3 x 1600 1339 4016 38.9 E2B1600 In=1600 0.9 58.3 T4L250 T4L250 T5L400 T5L630
1 x 2000 1673 1673 25.7 E2B2000 In=2000 0.9 25.7 T4H250 T4H250 T5H400 T5H630 S6L800/E1B
2 x 2000 6.25 1673 3347 24.7 E2B2000 In=2000 0.9 49.3 T4L250 T4L250 T5L400 T5L630 S8V
3 x 2000 1673 5020 47.5 E2B2000 In=2000 0.9 71.2 T4V250 T4V250 T5V400 T5V630
1 x 2500 6.25 2092 2092 31.8 E3N2500 In=2500 0.9 31.8 T4H250 T4H250 T5H400 T5H630 S7L1250/E1B
1 x 3125 6.25 2615 2615 39.2 E3N3200 In=3200 0.9 39.2 T4H250 T4H250 T5H400 T5H630 S8H

142 ABB SACE - Electrical devices

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3 Protection of electrical equipment

Circuit Breaker "B" (Feeder Circuit Breaker)

Feeder Circuit Breaker type and rated current
63 A 125 A 160 A 250 A 400 A 630 A 800 A 1250 A 1600 A 2000 A 2500 A 3200 A 4000 A
0
160
160
T1N160
160
T1N160
160
T2S160
T1N160
T2L160 T4N250
T1N160
T4N250 T4N250
T2S160
T4N250 T4N250 T5N400
T2L160 T4N250
T4N250 T4N250 T5N400
T4N250 T4N250
T4S250 T4S250 T5S400 T5S630
T4N250 T4N250 T5N400
T4H250 T4H250 T5H400 T5H630
T4H250 T4H250 T5H400 T5H630 E2B1600
T4N250 T4N250 T5N400
T4H250 T4H250 T5H400 T5H630 S6L800
T4H250 T4H250 T5H400 T5H630 E2B1600
T4N250 T4N250 T5N400 T5N630
T4H250 T4H250 T5H400 T5H630 S7L1250/E1B800 S7L1250/E1B1250
T4L250 T4L250 T5L400 T5L630 S8V2000/E2N1250 S8V2000/E2N1600 E2N2000
T4S250 T4S250 T5S400 T5S630 S6S800/E1B800
T4H250 T4H250 T5H400 T5H630 S8H2000/E2B1250 S8H2000/E2B1600
T4L250 T4L250 T5L400 T5L630 E3N2500
T4S250 T4S250 T5S400 T5S630 S6S800/E1B800
1SDC010037F0201

T4L250 T4L250 T5L400 T5L630 S8V2000/E2B1250 S8V2000/E2B1600 E2B2000

T4L250 T4L250 T5L400 T5L630 E3N2500 E3N3200
T4H250 T4H250 T5H400 T5H630 S6L800/E1B800 S7L1250/E1B1250
T4L250 T4L250 T5L400 T5L630 S8V2000/E2N1250 S8V2000/E2N1600 E2N2000 E3N2500
T4V250 T4V250 T5V400 T5V630 E2L1250 E2L1600 E3S2000 E3S2500 E3S3200 E4S4000
T4H250 T4H250 T5H400 T5H630 S7L1250/E1B800 S7L1250/E1B1250 S7L1600/E2B1600
T4H250 T4H250 T5H400 T5H630 S8H2000/E2B1250 S8H2000/E2B1600 E2B2000

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3 Protection of electrical equipment

NOTE
The tables refer to the previously specified conditions; the information for the
selection of circuit-breakers is supplied only with regard to the current in use
and the prospective short-circuit current. For a correct selection, other factors
such as selectivity, back-up protection, the decision to use limiting circuit-
breakers etc. must also be considered. Therefore, it is essential that the design
engineers carry out precise checks.
It must also be noted that the short-circuit currents given are determined using
the hypothesis of 750 MVA power upstream of the transformers, disregarding
the impedances of the busbars or the connections to the circuit-breakers.

Example:
Supposing the need to size breakers A1/A2/A3, on the LV side of the three
transformers of 630 kVA 20/0.4 kV with uk% equal to 4% and outgoing feeder
circuit-breakers B1/B2/B3 of 63-400-800 A:

A1 A2 A3

B1 B2 B3
1SDC010026F0001

63 A 400 A 800 A

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3 Protection of electrical equipment

From Table 2, corresponding to the row relevant to 3x630 kVA
transformers, it can be read that:

Level A circuit-breakers (LV side of transformer)

Trafo Ir (909 A) is the current that flows through the transformer circuit-breakers;
Busbar Ib (2727 A) is the maximum current that the transformers can supply;
Trafo Feeder Ik (42.8 kA) is the value of the short-circuit current to consider for
the choice of the breaking capacity of each of the transformer circuit-breakers;
S7S1250 or E1N1250 is the size of the transformer circuit-breaker;
In (1000 A) is the rated current of the transformer circuit-breaker (electronic
release chosen by the user);
Setting (0.95) indicates the set value of function L of the electronic release.

Level B circuit-breakers (outgoing feeder)

Busbar Ik (64.2 kA) is the short-circuit current due to the contribution of all
three transformers;
corresponding to 63 A, read circuit-breaker B1 Tmax T2H160;
corresponding to 400 A, read circuit-breaker B2 Tmax T5H400;
corresponding to 800 A, read circuit-breaker B3 Isomax S6L800 or E2N1250.

The choice made does not take into account discrimination/back-up

requirements. Refer to the relevant chapters for selections appropriate to the
various cases.

ABB SACE - Electrical devices 145

 4 Power factor correction

4.1 General aspects

In alternating current circuits, the current absorbed by the user can be
represented by two components:
U
- the active component IR, in phase with the supply voltage, is directly correlated
to the output (and therefore to the part of electrical energy transformed into
energy of a different type, usually electrical with different characteristics,
IR P
I S
mechanical, light and/or thermal);
- the reactive component IQ, in quadrature to the voltage, is used to produce
IQ Q the flow necessary for the conversion of powers through the electric or
magnetic field. Without this, there could be no flow of power, such as in the
core of a transformer or in the air gap of a motor.
In the most common case, in the presence of ohmic-inductive type loads, the
total current (I) lags in comparison with the active component IR.
In an electrical installation, it is necessary to generate and transmit, other than
the active power P, a certain reactive power Q, which is essential for the
conversion of electrical energy, but not available to the user. The complex of
the power generated and transmitted constitutes the apparent power S.

Power factor (cos) is defined as the ratio between the active component IR
and the total value of the current l; is the phase shifting between the voltage
U and the current l.
It results:
IR P
cos = = (1)
I S

The reactive demand factor (tan) is the relationship between the reactive power
and the active power:
Q
tan = (2)
P

146 ABB SACE - Electrical devices

 4.1 General aspects

4 Power factor correction

Table 1 shows some typical power factors:

Table 1: Typical power factor

Load cos tan

power factor reactive demand factor
Transformers (no load condition) 0.10.15 9.96.6
Motor (full load) 0.70.85 1.00.62
Motor (no load) 0.15 6.6
Metal working apparatuses:
- Arc welding 0.350.6 2.71.3
- Arc welding compensated 0.70.8 1.00.75
- Resistance welding: 0.40.6 2.31.3
- Arc melting furnace 0.750.9 0.90.5
Fluorescent lamps
- compensated 0.9 0.5
- uncompensated 0.40.6 2.31.3
Mercury vapour lamps 0.5 1.7
Sodium vapour lamp 0.650.75 1.20.9
AC DC converters 0.60.95 1.30.3
DC drives 0.40.75 2.30.9
AC drives 0.950.97 0.330.25
Resistive load 1 0

The power factor correction is the action increasing the power factor in a specific
section of the installation by locally supplying the necessary reactive power, so
as to reduce the current value to the equivalent of the power required, and
therefore the total power absorbed from the upstream side. Thus, both the line
as well as the supply generator can be sized for a lower apparent power value
required by the load.
In detail, as shown by Figure 1 and Figure 2, increasing the power factor of the
load:
- decreases the relative voltage drop urp per unit of active power transmitted;
- increases the transmittable active power and decreases the losses, the other
dimensioning parameters remaining equal.

ABB SACE - Electrical devices 147

 4.1 General aspects

4 Power factor correction

Figure 1: Relative voltage drop
Voltage drop per unit of active power transmitted
10

Cable cross section

Relative voltage drop

1SDC010039F0201
1
0.50
Load power factor

Figure 2: Transmittable active power

Active power increase with equal dimensioning factors
1000
original power factor
0.4 0.5 0.6

0.7 0.8 0.9

Active Power % increase

100

10
1SDC010040F0201

1
0.70 0.80 0.90 1.00
Improved power factor

148 ABB SACE - Electrical devices

 4.1 General aspects

4 Power factor correction

The distribution authority is responsible for the production and transmission of
the reactive power required by the user installations, and therefore has a series
of further inconveniences which can be summarized as:
- oversizing of the conductors and and of the components of the transmission
lines;
- higher Joule-effect losses and higher voltage drops in the components and
lines.
The same inconveniences are present in the distribution installation of the final
user. The power factor is an excellent index of the size of the added costs and
is therefore used by the distribution authority to define the purchase price of
the energy for the final user.
The ideal situation would be to have a cos slightly higher than the set reference
so as to avoid payment of legal penalties, and at the same time not to risk
having, with a cos too close to the unit, a leading power factor when the
power factor corrected device is working with a low load.
The distribution authority generally does not allow others to supply reactive
power to the network, also due to the possibility of unexpected overvoltages.

In the case of a sinusoidal waveform, the reactive power necessary to pass

from one power factor cos1 to a power factor cos2 is given by the formula:

Qc = Q2 - Q1 = P ( tan 1 - tan 2 ) (3)

where:
P is the active power;
Q1,1 are the reactive power and the phase shifting before power factor correction;
Q2,2 are the reactive power and the phase shifting after power factor correction;
Qc is the reactive power for the power factor correction.

P Q2
S2 Q2 Q1
Qc
S2
P
S1
Qc P Q1 S1

Power factor correction unit Motor

(reactive power generator)
1SDC010041F0201

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 4.1 General aspects

4 Power factor correction

Table 2 shows the value of the relationship

Qc
Kc = = tan 1 - tan 2 (4)
P
for different values of the power factor before and after the correction.

Table 2: Factor Kc
Kc cos2
cos1 0.80 0.85 0.90 0.91 0.92 0.93 0.94 0.95 0.96 0.97 0.98 0.99 1
0.60 0.583 0.714 0.849 0.878 0.907 0.938 0.970 1.005 1.042 1.083 1.130 1.191 1.333
0.61 0.549 0.679 0.815 0.843 0.873 0.904 0.936 0.970 1.007 1.048 1.096 1.157 1.299
0.62 0.515 0.646 0.781 0.810 0.839 0.870 0.903 0.937 0.974 1.015 1.062 1.123 1.265
0.63 0.483 0.613 0.748 0.777 0.807 0.837 0.870 0.904 0.941 0.982 1.030 1.090 1.233
0.64 0.451 0.581 0.716 0.745 0.775 0.805 0.838 0.872 0.909 0.950 0.998 1.058 1.201
0.65 0.419 0.549 0.685 0.714 0.743 0.774 0.806 0.840 0.877 0.919 0.966 1.027 1.169
0.66 0.388 0.519 0.654 0.683 0.712 0.743 0.775 0.810 0.847 0.888 0.935 0.996 1.138
0.67 0.358 0.488 0.624 0.652 0.682 0.713 0.745 0.779 0.816 0.857 0.905 0.966 1.108
0.68 0.328 0.459 0.594 0.623 0.652 0.683 0.715 0.750 0.787 0.828 0.875 0.936 1.078
0.69 0.299 0.429 0.565 0.593 0.623 0.654 0.686 0.720 0.757 0.798 0.846 0.907 1.049
0.70 0.270 0.400 0.536 0.565 0.594 0.625 0.657 0.692 0.729 0.770 0.817 0.878 1.020
0.71 0.242 0.372 0.508 0.536 0.566 0.597 0.629 0.663 0.700 0.741 0.789 0.849 0.992
0.72 0.214 0.344 0.480 0.508 0.538 0.569 0.601 0.635 0.672 0.713 0.761 0.821 0.964
0.73 0.186 0.316 0.452 0.481 0.510 0.541 0.573 0.608 0.645 0.686 0.733 0.794 0.936
0.74 0.159 0.289 0.425 0.453 0.483 0.514 0.546 0.580 0.617 0.658 0.706 0.766 0.909
0.75 0.132 0.262 0.398 0.426 0.456 0.487 0.519 0.553 0.590 0.631 0.679 0.739 0.882
0.76 0.105 0.235 0.371 0.400 0.429 0.460 0.492 0.526 0.563 0.605 0.652 0.713 0.855
0.77 0.079 0.209 0.344 0.373 0.403 0.433 0.466 0.500 0.537 0.578 0.626 0.686 0.829
0.78 0.052 0.183 0.318 0.347 0.376 0.407 0.439 0.474 0.511 0.552 0.599 0.660 0.802
0.79 0.026 0.156 0.292 0.320 0.350 0.381 0.413 0.447 0.484 0.525 0.573 0.634 0.776
0.80 0.130 0.266 0.294 0.324 0.355 0.387 0.421 0.458 0.499 0.547 0.608 0.750
0.81 0.104 0.240 0.268 0.298 0.329 0.361 0.395 0.432 0.473 0.521 0.581 0.724
0.82 0.078 0.214 0.242 0.272 0.303 0.335 0.369 0.406 0.447 0.495 0.556 0.698
0.83 0.052 0.188 0.216 0.246 0.277 0.309 0.343 0.380 0.421 0.469 0.530 0.672
0.84 0.026 0.162 0.190 0.220 0.251 0.283 0.317 0.354 0.395 0.443 0.503 0.646
0.85 0.135 0.164 0.194 0.225 0.257 0.291 0.328 0.369 0.417 0.477 0.620
0.86 0.109 0.138 0.167 0.198 0.230 0.265 0.302 0.343 0.390 0.451 0.593
0.87 0.082 0.111 0.141 0.172 0.204 0.238 0.275 0.316 0.364 0.424 0.567
0.88 0.055 0.084 0.114 0.145 0.177 0.211 0.248 0.289 0.337 0.397 0.540
0.89 0.028 0.057 0.086 0.117 0.149 0.184 0.221 0.262 0.309 0.370 0.512
0.90 0.029 0.058 0.089 0.121 0.156 0.193 0.234 0.281 0.342 0.484

150 ABB SACE - Electrical devices

 4.1 General aspects

4 Power factor correction

Example
Supposing the need to change from 0.8 to 0.93 the power factor of a three-
phase installation (Ur= 400 V) which absorbs an average power of 300 kW.
From Table 2, at the intersection of the column corresponding to the final power
factor (0.93), and the row corresponding to the starting power factor (0.8), the
value of Kc (0.355) can be read. The reactive power Qc which must be generated
locally shall be:

Qc = K c . P = 0.355 . 300 = 106.5 kvar

Due to the effect of power factor correction, the current absorbed decreases
from 540 A to 460 A (a reduction of approximately 15%).

Characteristics of power factor correction capacitor banks

The most economical means of increasing the power factor, especially for an
installation which already exists, is installing capacitors.
Capacitors have the following advantages:
- low cost compared with synchronous compensators and electronic power
converters;
- ease of installation and maintenance;
- reduced losses (less than 0.5 W/kvar in low voltage);
- the possibility of covering a wide range of powers and different load profiles,
simply supplying in parallel different combinations of components, each with
a relatively small power.

The disadvantages are sensitivity to overvoltages and to the presence of non-

linear loads.

The Standards applicable to power factor correction capacitors are as follows:

- IEC 60831-1 Shunt power capacitors of the self-healing type for a.c. systems
having a rated voltage up to and including 1000 V - Part 1: General - Perfor-
mance, testing and rating - Safety requirements - Guide for installation and
operation;

- IEC 60931-1 Shunt power capacitors of the non-self-healing type for a.c.
systems having a rated voltage up to and including 1000 V - Part 1: General-
Performance, testing and rating - Safety requirements - Guide for installation
and operation.

ABB SACE - Electrical devices 151

 4.1 General aspects

4 Power factor correction

The characteristics of a capacitor, given on its nameplate, are:

rated voltage Ur, which the capacitor must withstand indefinitely;

rated frequency fr (usually equal to that of the network);
rated power Qc, generally expressed in kvar (reactive power of the capacitor
bank).

From this data it is possible to find the size characteristics of the capacitors by
using the following formulae (5):

Single-phase Three-phase Three-phase

connection star-connection delta-connection

Qc Qc Qc
Capacity of the capacitor bank C= 2 C= 2 C= 2
2 fr U r 2 f r U r 2 f r U r 3

1SDC010005F0901
Rated current of the components Irc = 2 f r C U r Irc = 2 f r C U r / 3 I rc = 2 f r C U r

Line current I l = I rc I l = Irc I l = Irc 3

With three-phase systems, for the same reactive power, the star-connection
requires a capacity 3 times larger and subjects the capacitors to a voltage and
a current times less than the analogous delta-connection.
Capacitors are generally supplied with connected discharge resistance,
calculated so as to reduce the residual voltage at the terminals to 75 V in 3
minutes, as stated in the reference Standard.

4.2 Power factor correction method

Single PFC
Single or individual power factor correction is carried out by connecting a
capacitor of the correct value directly to the terminals of the device which absorbs
reactive power.
Installation is simple and economical: capacitors and load can use the same
overload and short-circuit protection, and are connected and disconnected
simultaneously.
The adjustment of cos is systematic and automatic with benefit not only to
the energy distribution authority, but also to the whole internal distribution system
of the user.
This type of power factor correction is advisable in the case of large users with
constant load and power factor and long connection times.
Individual PFC is usually applied to motors and fluorescent lamps. The capacitor
units or small lighting capacitors are connected directly to loads.

152 ABB SACE - Electrical devices

 4.2 Power factor connection method

4 Power factor correction

Individual PFC of motors
The usual connection diagrams are shown in the following Figure:

Starter Starter

Starter

1SDC010028F0001
M c M c M c
Diagram 1 Diagram 2 Diagram 3

In the case of direct connection (diagrams 1 and 2) there is a risk that after
disconnection of the supply, the motor will continue to rotate (residual kinetic
energy) and self-excite with the reactive energy supplied by the capacitor bank,
acting as an asynchronous generator. In this case, the voltage is maintained on
the load side of the switching and control device, with the risk of dangerous
overvoltages of up to twice the rated voltage value.

However, in the case of diagram 3, to avoid the risk detailed above, the normal
procedure is to connect the PFC bank to the motor only when it is running, and
to disconnect it before the disconnection of the motor supply.

As a general rule, for a motor with power Pr, it is advisable to use a PFC with
reactive power Qc below 90% of the reactive power absorbed by the no-load
motor Q0, at rated voltage Ur, to avoid a leading power factor.
Considering that under no-load conditions, the current absorbed I0 [A] is solely
reactive, if the voltage is expressed in volts, it results:

3 U r I 0
Qc = 0.9 Q0 = 0.9 [kvar] (6)
1000

The current I0 is generally given in the documentation supplied by the

manufacturer of the motor.

ABB SACE - Electrical devices 153

 4.2 Power factor connection method

4 Power factor correction

Table 3 shows the values of reactive power for power factor correction of some
ABB motors, according to the power and the number of poles.

Table 3: Reactive power for power factor motor correction

Pr Qc Before PFC After PFC
[kW] [kvar] cosr Ir [A] cos2 I2 [A]

400V / 50 Hz / 2 poles / 3000 r/min

7.5 2.5 0.89 13.9 0.98 12.7
11 2.5 0.88 20 0.95 18.6
15 5 0.9 26.5 0.98 24.2
18.5 5 0.91 32 0.98 29.7
22 5 0.89 38.5 0.96 35.8
30 10 0.88 53 0.97 47.9
37 10 0.89 64 0.97 58.8
45 12.5 0.88 79 0.96 72.2
55 15 0.89 95 0.97 87.3
75 15 0.88 131 0.94 122.2
90 15 0.9 152 0.95 143.9
110 20 0.86 194 0.92 181.0
132 30 0.88 228 0.95 210.9
160 30 0.89 269 0.95 252.2
200 30 0.9 334 0.95 317.5
250 40 0.92 410 0.96 391.0
315 50 0.92 510 0.96 486.3

400V / 50 Hz / 4 poles / 1500 r/min

7.5 2.5 0.86 14.2 0.96 12.7
11 5 0.81 21.5 0.96 18.2
15 5 0.84 28.5 0.95 25.3
18.5 7.5 0.84 35 0.96 30.5
22 10 0.83 41 0.97 35.1
30 15 0.83 56 0.98 47.5
37 15 0.84 68 0.97 59.1
45 20 0.83 83 0.97 71.1
55 20 0.86 98 0.97 86.9
75 20 0.86 135 0.95 122.8
90 20 0.87 158 0.94 145.9
110 30 0.87 192 0.96 174.8
132 40 0.87 232 0.96 209.6
160 40 0.86 282 0.94 257.4
200 50 0.86 351 0.94 320.2
250 50 0.87 430 0.94 399.4
315 60 0.87 545 0.93 507.9

154 ABB SACE - Electrical devices

 4.2 Power factor connection method

4 Power factor correction

Pr Qc Before PFC After PFC

[kW] [kvar] cosr Ir [A] cos2 I2 [A]

400V / 50 Hz / 6 poles / 1000 r/min

7.5 5 0.79 15.4 0.98 12.4
11 5 0.78 23 0.93 19.3
15 7.5 0.78 31 0.94 25.7
18.5 7.5 0.81 36 0.94 30.9
22 10 0.81 43 0.96 36.5
30 10 0.83 56 0.94 49.4
37 12.5 0.83 69 0.94 60.8
45 15 0.84 82 0.95 72.6
55 20 0.84 101 0.96 88.7
75 25 0.82 141 0.93 123.9
90 30 0.84 163 0.95 144.2
110 35 0.83 202 0.94 178.8
132 45 0.83 240 0.95 210.8
160 50 0.85 280 0.95 249.6
200 60 0.85 355 0.95 318.0
250 70 0.84 450 0.94 404.2
315 75 0.84 565 0.92 514.4

400V / 50 Hz / 8 poles / 750 r/min

7.5 5 0.7 18.1 0.91 13.9
11 7.5 0.76 23.5 0.97 18.4
15 7.5 0.82 29 0.97 24.5
18.5 7.5 0.79 37 0.93 31.5
22 10 0.77 45 0.92 37.5
30 12.5 0.79 59 0.93 50.0
37 15 0.78 74 0.92 62.8
45 20 0.78 90 0.93 75.4
55 20 0.81 104 0.93 90.2
75 30 0.82 140 0.95 120.6
90 30 0.82 167 0.93 146.6
110 35 0.83 202 0.94 178.8
132 50 0.8 250 0.93 214.6

ABB SACE - Electrical devices 155

 4.2 Power factor connection method

4 Power factor correction

Example
For a three-phase asynchronous motor, 110 kW (400 V - 50 Hz - 4 poles), the
PFC power suggested in the table is 30 kvar.

Individual power factor correction of three-phase transformers

A transformer is an electrical device of primary importance which, due to the

system requirements, is often constantly in service.
In particular, in installations constituted by several transformer substations, it is
advisable to carry out power factor correction directly at the transformer.
In general, the PFC power (Qc) for a transformer with rated power Sr [kVA]
should not exceed the reactive power required under minimum reference load
conditions.
Reading the data from the transformer nameplate, the percentage value of the
no-load current i0%, the percentage value of the short-circuit voltage uk%, the
iron losses Pfe and the copper losses Pcu [kW], the PFC power required is
approximately:

2 2
i % 2 2 u % 2 i % 2 u %
Qc = 0 Sr Pfe + K L k Sr Pcu 0 Sr + K L k Sr [kvar] (7)
100 100 100 100

where KL is the load factor, defined as the relationship between the minimum
reference load and the rated power of the transformer.

Example
Supposing the need for PFC of a 630 kVA oil-distribution transformer which
supplies a load which is less than 60% of its rated power.
From the data on the transformer nameplate:
i0% = 1.8%
uk% = 4%
Pcu = 8.9 kW
Pfe = 1.2 kW
The PFC power of the capacitor bank connected to the transformer is:

2 2 2 2
i % 2 2 u % 2 1.8% 4%
Qc = 0 Sr Pfe + K L k Sr Pcu = 630 1.22+ 0.62 630 8.92 =19.8 kvar
100 100 100 100

while, when using the simplified formula, the result is:

i % 2 u % 1.8% 4%
Qc = 0 Sr + K L k Sr = 630 + 0.62 630 = 20.4 kvar
100 100 100 100

156 ABB SACE - Electrical devices

 4.2 Power factor connection method

4 Power factor correction

Table 4 shows the reactive power of the capacitor bank Qc [kvar] to be connected
on the secondary side of an ABB transformer, according to the different minimum
estimated load levels.
Table 4: PFC reactive power for ABB transformers
Qc [kvar]
Sr uk% io% Pfe Pcu load factor KL
[kVA] [%] [%] [kW] [kW] 0 0.25 0.5 0.75 1

Oil Distribution Transformer MV-LV

50 4 2.9 0.25 1.35 1.4 1.5 1.8 2.3 2.9
100 4 2.5 0.35 2.30 2.5 2.7 3.3 4.3 5.7
160 4 2.3 0.48 3.20 3.6 4 5 6.8 9.2
200 4 2.2 0.55 3.80 4.4 4.8 6.1 8.3 11
250 4 2.1 0.61 4.50 5.2 5.8 7.4 10 14
315 4 2 0.72 5.40 6.3 7 9.1 13 18
400 4 1.9 0.85 6.50 7.6 8.5 11 16 22
500 4 1.9 1.00 7.40 9.4 11 14 20 28
630 4 1.8 1.20 8.90 11 13 17 25 35
800 6 1.7 1.45 10.60 14 16 25 40 60
1000 6 1.6 1.75 13.00 16 20 31 49 74
1250 6 1.6 2.10 16.00 20 24 38 61 93
1600 6 1.5 2.80 18.00 24 30 47 77 118
2000 6 1.2 3.20 21.50 24 31 53 90 142
2500 6 1.1 3.70 24.00 27 37 64 111 175
3150 7 1.1 4.00 33.00 34 48 89 157 252
4000 7 1.4 4.80 38.00 56 73 125 212 333

Cast Resin Distribution Transformer MV-LV

100 6 2.3 0.50 1.70 2.2 2.6 3.7 5.5 8
160 6 2 0.65 2.40 3.1 3.7 5.5 8.4 12
200 6 1.9 0.85 2.90 3.7 4.4 6.6 10 15
250 6 1.8 0.95 3.30 4.4 5.3 8.1 13 19
315 6 1.7 1.05 4.20 5.3 6.4 9.9 16 24
400 6 1.5 1.20 4.80 5.9 7.3 12 19 29
500 6 1.4 1.45 5.80 6.8 8.7 14 23 36
630 6 1.3 1.60 7.00 8 10 17 29 45
800 6 1.1 1.94 8.20 8.6 12 20 35 56
1000 6 1 2.25 9.80 9.7 13 25 43 69
1250 6 0.9 3.30 13.00 11 15 29 52 85
1600 6 0.9 4.00 14.50 14 20 38 67 109
2000 6 0.8 4.60 15.50 15 23 45 82 134
2500 6 0.7 5.20 17.50 17 26 54 101 166
3150 8 0.6 6.00 19.00 18 34 81 159 269

Example
For a 630 kVA oil-distribution transformer with a load factor of 0.5, the necessary
PFC power is 17 kvar.

ABB SACE - Electrical devices 157

 4.2 Power factor connection method

4 Power factor correction

PFC in groups

1SDC010029F0001
Group of loads to be power factor corrected

This consists of local power factor correction of groups of loads with similar
functioning characteristics by installing a dedicated capacitor bank.
This method achieves a compromise between the economical solution and the
correct operation of the installation, since only the line downstream of the
installation point of the capacitor bank is not correctly exploited.

Centralized PFC

1SDC010030F0001

C
LV
Feeders

The daily load profile is of fundamental importance for the choice of the most
suitable type of power factor correction.
In installations, in which not all loads function simultaneously and/or in which
some loads are connected for only a few hours a day, the solution of using
single PFC becomes unsuitable as many of the capacitors installed could stay
idle for long periods.
In the case of installations with many loads occasionally functioning, thus having
a high installed power and a quite low average power absorption by the loads
which function simultaneously, the use of a single PFC system at the installation
origin ensures a remarkable decrease in the total power of the capacitors to be
installed.

158 ABB SACE - Electrical devices

 4.2 Power factor connection method

4 Power factor correction

Centralized PFC normally uses automatic units with capacitor banks divided
into several steps, directly installed in the main distribution switchboards; the
use of a permanently connected capacitor bank is only possible if the absorption
of reactive energy is fairly regular throughout the day.
The main disadvantage of centralized PFC is that the distribution lines of the
installation, downstream of the PFC device, must be dimensioned taking into
account the full reactive power required by the loads.

4.3 Circuit-breakers for the protection and

switching of capacitor banks

The circuit-breakers for the protection and switching of capacitor banks in LV

shall:

1. withstand the transient currents which occur when connecting and

disconnecting the banks. In particular, the instantaneous magnetic and
electronic releases shall not trip due to these peak currents;
2. withstand the periodic or permanent overcurrents due to the voltage
harmonics and to the tolerance (+15%) of the rated value of capacity;
3. perform a high number of no-load and on-load operations, also with high
frequency;
4. be coordinated with any external device (contactors).

Furthermore, the making and breaking capacity of the circuit-breaker must be

adequate to the short- circuit current values of the installation.

Standards IEC 60831-1 and 60931-1 state that:

- the capacitors shall normally function with an effective current value up to
130% of their rated current Irc (due to the possible presence of voltage
harmonics in the network);
- a tolerance of +15% on the value of the capacity is allowed.
The maximum current which can be absorbed by the capacitor bank Icmax is:

Qc
Ic max = 1.3 1.15 1.5 I rc (8)
3 U r
Therefore:
- the rated current of the circuit-breaker shall be greater than 1.5Irc;
- the overload protection setting shall be equal to 1.5Irc.

The connection of a capacitor bank, similar to a closing operation under short-

circuit conditions, associated with transient currents with high frequency (115
kHz), of short duration (13 ms), with high peak (25200 Irc).
Therefore:
- the circuit-breaker shall have an adequate making capacity;
- the setting of the instantaneous short-circuit protection must not cause
unwanted trips.

ABB SACE - Electrical devices 159

 4.3 Circuit-breakers for the protection and switching of capacitor banks

4 Power factor correction

The second condition is generally respected:
for thermomagnetic releases, the magnetic protection shall be set at a value
not less than 10Icmax
Qr
I3 10 Icmax = 15Irc= 15 (9)
3 U r
for electronic releases, the instantaneous short-circuit protection shall be
deactivated (I3 = OFF).
Hereunder, the selection tables for circuit-breakers: for the definition of the version
according to the required breaking capacity, refer to Volume 1, Chapter 3.1
General characteristics.
The following symbols are used in the tables (they refer to maximum values):
- InCB = rated current of the protection release [A];
- Irc= rated current of the connected capacitor bank [A];
- QC= power of the capacitor bank which can be connected [kvar] with reference
to the indicated voltage and 50 Hz frequency;
- Nmech = number of mechanical operations;
- fmech = frequency of mechanical operations [op/h];
- Nel = number of electrical operations with reference to a voltage of 415 V for
Tmax and Isomax moulded-case circuit breakers (Tables 5 and 6), and to a
voltage of 440 V for Emax air circuit-breakers (Table 7);
- fel = frequency of electrical operations [op/h].
Table 5: Selection table for Tmax moulded-case circuit-breakers
InCB Irc QC [kvar] Nmech fmech Nel fel
CB Type [A] [A] 400 V 440 V 500 V 690 V [op/h] [op/h]
T1 B-C-N 160 160 107 74 81 92 127 25000 240 8000 120
T2 N-S-H-L 160* 160 107 74 81 92 127 25000 240 8000 120
T3 N-S 250* 250 167 115 127 144 199 25000 240 8000 120
T4 N-S-H-L-V 250 250 167 115 127 144 199 20000 240 8000 120
T4 N-S-H-L-V 320 320 213 147 162 184 254 20000 240 6000 120
T5 N-S-H-L-V 400 400 267 185 203 231 319 20000 120 7000 60
T5 N-S-H-L-V 630 630 420 291 320 364 502 20000 120 5000 60
* for plug-in version reduce the maximum power of the capacitor bank by 10%

Table 6: Selection table for SACE Isomax S moulded-case circuit-breakers

InCB Irc QC [kvar] Nmech fmech Nel fel
S6 N-S-H-L 800 800 533 369 406 462 637 20000 120 5000 60
S7 S-H-L 1250 1250 833 577 635 722 996 10000 120 7000 20
S7 S-H-L 1600 1600 1067 739 813 924 1275 10000 120 5000 20
S8 H-V 2000 2000 1333 924 1016 1155 1593 10000 120 3000 20
S8 H-V 2500 2500 1667 1155 1270 1443 1992 10000 120 2500 20
S8 H-V 3200 3200 2133 1478 1626 1847 2550 10000 120 1500 10

160 ABB SACE - Electrical devices

 4.3 Circuit-breakers for the protection and switching of capacitor banks

4 Power factor correction

Table 7: Selection table for SACE Emax air circuit-breakers
InCB Irc QC [kvar] Nmech fmech Nel fel
CB Type [A] [A] 400 V 440 V 500 V 690 V [op/h] [op/h]
E1 B N 1250 834 578 636 722 997 25000 60 10000 30
E2 B-N 1250 834 578 636 722 997 25000 60 15000 30
E2 B-N 1600 1067 739 813 924 1275 25000 60 12000 30
E2 B-N 2000 1334 924 1017 1155 1594 25000 60 10000 30
E3 N-S-H 1250 834 578 636 722 997 20000 60 12000 20
E3 N-S-H 1600 1067 739 813 924 1275 20000 60 10000 20
E3 N-S-H 2000 1334 924 1017 1155 1594 20000 60 9000 20
E3 N-S-H 2500 1667 1155 1270 1444 1992 20000 60 8000 20
E3 N-S-H 3200 2134 1478 1626 1848 2550 20000 60 6000 20
E4 S-H 3200 2134 1478 1626 1848 2550 15000 60 7000 10
E6 H-V 3200 2134 1478 1626 1848 2550 12000 60 5000 10

ABB SACE - Electrical devices 161

 5 Protection of human beings

5.1 General aspects: effects of current on

human beings
Danger to persons due to contact with live parts is caused by the flow of the
current through the human body. The effects are:

- tetanization: the muscles affected by the current flow involuntary contract

and letting go of gripped conductive parts is difficult. Note: very high currents
do not usually induce muscular tetanization because, when the body touches
such currents, the muscular contraction is so sustained that the involuntary
muscle movements generally throw the subject away from the conductive
part;

- breathing arrest: if the current flows through the muscles controlling the
lungs, the involuntary contraction of these muscles alters the normal respiratory
process and the subject may die due to suffocation or suffer the consequences
of traumas caused by asphyxia;

- ventricular fibrillation: the most dangerous effect is due to the superposition

of the external currents with the physiological ones which, by generating
uncontrolled contractions, induce alterations of the cardiac cycle. This anomaly
may become an irreversible phenomenon since it persists even when the
stimulus has ceased;

- burns: they are due to the heating deriving, by Joule effect, from the current
passing through the human body.

The Standard IEC 60479-1 Effects of current on human being and livestock
is a guide about the effects of current passing through the human body to
be used for the definition of electrical safety requirements. This Standard shows,
on a time-current diagram, four zones to which the physiological effects of
alternating current (15 100 Hz) passing through the human body have been
related.

162 ABB SACE - Electrical devices

 5.1 General aspect: effects of current on human beings

5 Protection of human beings

Figure 1: Time-current zones of the effects of alternating current on
the human body
ms 10.000

1SDC010042F0201
a b c1 c2 c3
5.000
AC-4.1
AC-4.2
2.000
AC-4.3
1.000
Duration of current flow t

500
AC-1 AC-2 AC-3 AC-4
200

100

50

20

10
0,1 0,2 0,5 1 2 5 10 20 50 100 200 500 1.000 2.000 5.000 10.000
Body current IB mA
Zone Zone
designation limits Physiological effects
AC-1 Up to 0.5 mA Usually no reaction.
line a
AC-2 0.5 mA Usually no harmful physiological effects.
up to
line b*
AC-3 Line b Usually no organic damage to be expected. Likelihood of cramplike
up to muscular contractions and difficulty in breathing for durations of
curve c1 current-flow longer than 2 s. Reversible disturbances of formation and
conduction of impulses in the heart, including atrial fibrillation and
transient cardiac arrest without ventricular fibrillation increasing with
current magnitude and time.
AC-4 Above Increasing with magnitude and time, dangerous pathophysiological
curve c1 effects such as cardiac arrest, breathing arrest and severe burns may
occur in addition to the effects of zone 3.
AC-4.1 c1 - c2 Probability of ventricular fibrillation increasing up to about 5%.
AC-4.2 c2 - c3 Probability of ventricular fibrillation up to about 50%.
AC-4.3 Beyond Probability of ventricular fibrillation above 50%.
curve c3
* For durations of current-flow below 10 ms, the limit for the body current for line b
remains constant at a value of 200 mA.

This Standard gives also a related figure for direct current.

By applying Ohms law it is possible to define the safety curve for the allowable
voltages, once the human body impedance has been calculated. The electrical
impedance of the human body depends on many factors. The above mentioned
Standard gives different values of impedance as a function of the touch voltage
and of the current path.

ABB SACE - Electrical devices 163

 5.1 General aspect: effects of current on human beings

5 Protection of human beings

The Standard IEC 60479-1 has adopted precautionary values for the impedance
reported in the figure so as to get the time-voltage safety curve (Figure 2) related
to the total touch voltage UT (i.e. the voltage which, due to an insulation failure,
is present between a conductive part and a point of the ground sufficiently far,
with zero potential).
This represents the maximum no-load touch voltage value; thus, the most
unfavorable condition is taken into consideration for safetys sake.

Figure 2: Safety curve

2
t [s] 10

10

10-1
1SDC010031F0001

10-2
10 10 2 10 3
UT [V]
From this safety curve it results that for all voltage values below 50 V, the tolerance
time is indefinite; at 50 V the tolerance time is 5 s. The curve shown in the figure
refers to an ordinary location; in particular locations, the touch resistance of the
human body towards earth changes and consequently the tolerable voltage
values for an indefinite time shall be lower than 25 V.
Therefore, if the protection against indirect contact is obtained through the
disconnection of the circuit, it is necessary to ensure that such breaking is
carried out in compliance with the safety curve for any distribution system.

164 ABB SACE - Electrical devices

 5 Protection of human beings

5.2 Distribution systems

The earth fault modalities and the consequences caused by contact with live
parts, are strictly related to the neutral conductor arrangement and to the
connections of the exposed conductive parts.

For a correct choice of the protective device, it is necessary to know which is

the distribution system of the plant.
IEC 60364-1 classifies the distribution systems with two letters.

The first letter represents the relationship of the power system to earth:
- T: direct connection of one point to earth, in alternating current systems,
generally the neutral point;
- I: all live parts isolated from earth, or one point, in alternating current systems,
generally the neutral point, connected to earth through an impedance.

The second letter represents the relationship of the exposed conductive parts
of the installation to earth:
- T: direct electrical connection of the exposed conductive parts to earth;
- N: direct electrical connection of the exposed conductive parts to the earthed
point of the power system.

Subsequent letters, if any, represent the arrangement of neutral and protective

conductors:
- S: protective function is provided by a conductor separate from the neutral
conductor;
- C: neutral and protective functions combined as a single conductor (PEN
conductor).

Three types of distribution system are considered:

TT System
L1
L2
L3
N
1SDC010032F0001

PE

TN System
(TN-C) (TN-S)
L1
L2
L3
PEN N
1SDC010033F0001

PE

ABB SACE - Electrical devices 165

 5.2 Distribution systems

5 Protection of human beings

IT System L1
L2
L3

1SDC010034F0001
PE

In TT systems, the neutral conductor and the exposed conductive parts are
connected to earth electrodes electrically independent; the fault current flows
towards the power supply neutral point through earth (Fig. 1):

Figure 1: Earth fault in TT systems

Ik
L1
L2
L3
N

1SDC010035F0001
RB RA
Ik

In TT installations, the neutral conductor is connected to the supply star center,

it is usually distributed and has the function of making the phase voltage (e.g.
230 V) available, useful for single-phase load supply. The exposed conductive
parts, on the contrary, singularly or collectively, are locally connected to earth.
TT systems are generally used for civil installations.
TN systems are typically used when the power supply is distributed to loads
having their own electrical substation. The neutral conductor is directly earthed
in the substation; the exposed conductive parts are connected to the same
earthing point of the neutral conductor, and can be locally earthed.
Three types of TN system are considered according to the arrangement of
neutral and protective conductors:

1. TN-C neutral and protective functions are combined in a single conductor

(PEN conductor);
2. TN-S neutral and protective conductors are always separated;
3. TN-C-S neutral and protective functions are combined in a single conductor
in a part of the system (PEN) and are separated in another part (PE + N).

166 ABB SACE - Electrical devices

 5.2 Distribution systems

5 Protection of human beings

In TN systems, the fault current flows towards the power supply neutral point
through a solid metallic connection, practically without involving the earth
electrode (Figure 2).
Figure 2: Earth fault in TN systems

Ik
L1
L2
L3
PEN
0 (TN-C) Ik (TN-S)
PE N

1SDC010036F0001
IT systems have no live parts directly connected to earth, but they can be
earthed through a sufficiently high impedance. Exposed conductive parts shall
be earthed individually, in groups or collectively to an independent earthing
electrode.
The earth fault current flows towards the power supply neutral point through
the earthing electrode and the line conductor capacitance (Figure 3).

Figure 3: Earth fault in IT systems

L1
L2
L3
Ik

C3 C2 C1
1SDC010037F0001

Ik

These distribution systems are used for particular plants, where the continuity
of supply is a fundamental requirement, where the absence of the supply can
cause hazards to people or considerable economical losses, or where a low
value of a first earth fault is required. In these cases, an insulation monitoring
device shall be provided for optical or acoustic signalling of possible earth
faults, or failure of the supplied equipment.

ABB SACE - Electrical devices 167

 5 Protection of human beings

5.3 Protection against both direct and

indirect contact
Contacts of a person with live parts can be divided in two categories:
- direct contacts;
- indirect contacts.
A direct contact occurs when a part of the human body touches a part of the
plant, usually live (bare conductors, terminals, etc.).
A contact is indirect when a part of the human body touches an exposed
conductive parts, usually not live, but with voltage presence due to a failure or
wear of the insulating materials.

The measures of protection against direct contact are:

- insulation of live parts with an insulating material which can only be removed
by destruction (e.g. cable insulation);
- barriers or enclosures: live parts shall be inside enclosures or behind barriers
providing at least the degree of protection IPXXB or IP2X; for horizontal surfaces
the degree of protection shall be of at least IPXXD or IP4X (for the meaning of
the degree of protection codes please refer to Volume 1, Chapter 6.1 Electrical
switchboards);
- obstacles: the interposition of an obstacle between the live parts and the
operator prevents unintentional contacts only, but not an intentional contact
by the removal of the obstacle without particular tools;
- placing out of reach: simultaneously accessible parts at different potentials
shall not be within arms reach.

An additional protection against direct contact can be obtained by using residual

current devices with a rated operating residual current not exceeding 30 mA. It
must be remembered that the use of a residual current device as a mean of
protection against direct contacts does not obviate the need to apply one of
the above specified measures of protection.

The measures of protection against indirect contact are:

- automatic disconnection of the supply: a protective device shall automatically
disconnect the supply to the circuit so that the touch voltage on the exposed
conductive part does not persist for a time sufficient to cause a risk of harmful
physiological effect for human beings;
- supplementary insulation or reinforced insulation, e.g. by the use of Class II
components;

168 ABB SACE - Electrical devices

 5.3 Protection against both direct and indirect contact

5 Protection of human beings

- non-conducting locations: locations with a particular resistance value of
insulating floors and walls ( 50 k for Ur 500 V; 100 k for Ur > 500 V)
and without protective conductors inside
- electrical separation, e.g. by using an isolating transformer to supply the circuit;
- earth-free local equipotential bonding: locations where the exposed conductive
parts are connected together but not earthed.

Finally, the following measures provide combined protection against both direct
and indirect contact:
- SELV (Safety Extra Low Voltage) system and PELV (Protective Extra Low
Voltage) system;
- FELV (Functional Extra Low Voltage) system.

The protection against both direct and indirect contact is ensured if the
requirements stated in 411 from IEC 60364-4-41 are fulfilled; particularly:
- the rated voltage shall not exceeds 50 V ac r.m.s. and 120 V ripple-free dc;
- the supply shall be a SELV or PELV source;
- all the installation conditions provided for such types of electrical circuits shall
be fulfilled.

A SELV circuit has the following characteristics:

1) it is supplied by an independent source or by a safety source. Independent
sources are batteries or diesel-driven generators. Safety sources are supplies
obtained through an isolating transformer;
2) there are no earthed points. The earthing of both the exposed conductive
parts as well as of the live parts of a SELV circuit is forbidden;
3) it shall be separated from other electrical systems. The separation of a SELV
system from other circuits shall be guaranteed for all the components; for
this purpose, the conductors of the SELV circuit may be contained in multi-
conductor cables or may be provided with an additional insulating sheath.

A PELV circuit has the same prescription of a SELV system, except for the
prohibition of earthed points; in fact in PELV circuits, at least one point is always
earthed.

ABB SACE - Electrical devices 169

 5.3 Protection against both direct and indirect contact

5 Protection of human beings

FELV circuits are used when for functional reasons the requirements for SELV
or PELV circuits cannot be fulfilled; they require compliance with the following rules:
a) protection against direct contact shall be provided by either:
- barriers or enclosures with degree of protection in accordance with what
stated above (measures of protection against direct contact);
- insulation corresponding to the minimum test voltage specified for the
primary circuit. If this test is not passed, the insulation of accessible non-
conductive parts of the equipment shall be reinforced during erection so
that it can withstand a test voltage of 1500 V ac r.m.s. for 1 min.;
b) protection against indirect contact shall be provided by:
- connection of the exposed conductive parts of the equipment of the FELV
circuit to the protective conductor of the primary circuit, provided that the
latter is subject to one of the measures of protection against direct contact;
- connection of a live conductor of the FELV circuit to the protective
conductor of the primary circuit provided that an automatic disconnection
of the supply is applied as measure of protection;
c) plugs of FELV systems shall not be able to enter socket-outlets of other
voltage systems, and plugs of other voltage systems shall not be able to
enter socket-outlets of FELV systems.
Figure 1 shows the main features of SELV, PELV and FELV systems.

Figure 1: SELV, PELV, FELV systems

safety isolating transformer no safety source,

or equivalent source, connection to earth
connection to earth is admissible
is admissible
L1
L2
L3
N
PE
PE PE

safety isolating E E
transformer
or equivalent
source,
no earthing
SELV PELV FELV

Class II
equipment
1SDC010043F0201

PELV circuit FELV circuit

voltage limits for E earth connections by estraneous conductive parts,
extra-low voltages: e.g. by metal pipe or structural steelwork

50 V ac PE protective conductor
120 V dc earth electrode

Note 1: Overcurrent protective devices are not shown in this figure.

170 ABB SACE - Electrical devices

 5 Protection of human beings

5.4 TT System

An earth fault in a TT system involves the circuit represented in Figure 1:

Figure 1: Earth fault in TT system

Ik
L1
L2
L3
N

1SDC010035F0001
RB RA
Ik

The fault current involves the secondary winding of the transformer, the phase
conductor, the fault resistance, the protective conductor and the earth electrode
resistance (plant earthing system (RA) and earthing system which the neutral is
connected to (RB)).
According to IEC 60364-4 requirements, the protective devices must be co-
ordinated with the earthing system in order to rapidly disconnect the supply, if
the touch voltage reaches harmful values for the human body.
Assuming 50 V (25 V for particular locations) as limit voltage value, the condition
to be fulfilled in order to limit the touch voltage on the exposed conductive
parts under this limit value is:

50 50
Rt or Rt
Ia I n

where:
Rt is the total resistance, equal to the sum of the earth electrode (RA)
and the protective conductor for the exposed conductive parts [];
Ia is the current causing the automatic operation within 5 s of the
overcurrent protective device, read from the tripping curve of the
device [A];
In is the rated residual operating current, within one second, of the
circuit-breaker [A].

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 5.4 TT System

5 Protection of human beings

From the above, it is clear that Rt value is considerably different when using
automatic circuit breakers instead of residual current devices.
In fact, with the former, it is necessary to obtain very low earth resistance values
(usually less than 1 ) since the 5 s tripping current is generally high, whereas,
with the latter, it is possible to realize earthing systems with resistance value of
thousands of ohms, which are easier to be carried out.

Table 1 reports the maximum earth resistance values which can be obtained
using residual current devices, with reference to an ordinary location (50 V):

Table 1: Earth resistance values

In Rt
[A] []
0.01 5000
0.03 1666
0.1 500
0.3 166
0.5 100
3 16
10 5
30 1.6

Example:
Assuming to provide protection by using an automatic circuit breaker Tmax
T1B160 In125, the trip current value in less than 5 s, read from the tripping
characteristic curve, is about 750 A, when starting from cold conditions (the
worst case for thermomagnetic releases).

So:
50
Rt = 0.06
750

In order to provide the required protection, it must be necessary to carry out an

earthing system with an earth resistance Rt 0.06 , which is not an easily
obtainable value.

On the contrary, by using the same circuit breaker mounting ABB SACE RC221
residual current release, with rated residual operating current In = 0.03 A, the
required value of earth resistance is:

50
Rt = 1666.6
0.03

which can be easily obtained in practice.

172 ABB SACE - Electrical devices

 5.4 TT System

5 Protection of human beings

104 s

103 s

102 s

10s

5s

1s

10-1 s

1SDC010038F0001
10-2 s

750 A

0.1kA 1kA 10kA

In an electrical installation with a common earthing system and loads protected

by devices with different tripping currents, for the achievement of the coordination
of all the loads with the earthing system, the worst case - represented by the
device with the highest tripping current - shall be considered.

As a consequence, when some feeders are protected by overcurrent devices

and some others by residual current devices, all the advantages deriving from
the use of residual current releases are nullified, since the Rt shall be calculated
on the basis of the I5s of the overcurrent device and since it is the highest
tripping current between these two kind of devices.

Therefore, it is advisable to protect all the loads of a TT system by means of

residual current circuit-breakers coordinated with the earthing system to obtain
the advantages of both a quick disconnection of the circuit when the fault occurs
as well as an earthing system which can be easily accomplished.

ABB SACE - Electrical devices 173

 5 Protection of human beings

5.5 TN System

An earth fault in a TN system involves the circuit represented in Figure 1:

Figure 1: Earth fault in TN system

Ik
L1
L2
L3
PEN
0 (TN-C) Ik (TN-S)
PE N

1SDC010036F0001
The fault loop does not affect the earthing system and is basically formed by
the connection in series of the phase conductor and of the protective conductor.
To provide a protection with automatic disconnection of the circuit, according
to IEC 60364-4 prescriptions, the following condition shall be fulfilled:

Z s . I a U0

where:
Zs is the impedance of the fault loop comprising the source, the live
conductor up to the point of the fault and the protective conductor
between the point of the fault and the source [];
U0 is the nominal ac r.m.s. voltage to earth [V];
Ia is the current causing the automatic operation of the disconnecting
protective device within the time stated in Table 1, as a function of
the rated voltage U0 or, for distribution circuits, a conventional
disconnecting time not exceeding 5 s is permitted [A]; if the protection
is provided by means of a residual current device, Ia is the rated
residual operating current In.

Table 1: Maximum disconnecting times for TN system

U0 [V] Disconnecting time [s]
120 0.8
230 0.4
400 0.2
> 400 0.1

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 5.5 TN System

5 Protection of human beings

In TN installations, an earth fault with low impedance occurring on the LV side
causes a short circuit current with quite high value, due to the low value of the
impedance of the fault loop. The protection against indirect contact can be
provided by automatic circuit-breakers: it is necessary to verify that the operating
current within the stated times is lower than the short-circuit current.

The use of residual current devices improves the conditions for protection in
particular when the fault impedance doesnt have a low value, thus limiting the
short-circuit current; this current can persist for quite long time causing
overheating of the conductors and fire risks.

Finally, it is important to highlight the fact that the residual current devices cannot
be used in TN-C system, since the neutral and protective functions are provided
by a unique conductor: this configuration prevents the residual current device
from working.

Example:

In the plant represented in Figure 2, the earth fault current is:

IkLG = 3 kA

The rated voltage to earth is 230 V, therefore, according to Table 1, it shall be

verified that:
U0
I a ( 0.4s) = I kLG = 3 kA
Zs

Figure 2

-U1
U Ur = 400 V
LLLN / TN-S

-QF1
T1B 160 In125

-WC1
3x(1x50)+1x(1x25)+1G25
PVC Cu
dV = 0.38%
Iz = 134.0 A
L = 20 m
-B1
1SDC010039F0001

Ik LG = 3.0 kA

Sr = 70.00 kVA
L cos = 0.90

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 5.5 TN System

5 Protection of human beings

From the tripping curve (Figure 3), it is clear that the circuit-breaker trips in 0.4 s
for a current value lower than 950 A. As a consequence, the protection against
indirect contact is provided by the same circuit-breaker which protects the
cable against short-circuit and overload, without the necessity of using an
additional residual current device.

Figure 3: LG Time-Current curves

IkLG=3.0 kA
104 s

103 s
3x(1x50)+1x(1x25)+1G25

102 s

T1B160
In125
101 s

1s

0.4s 1SDC010040F0001

10-1 s

950 A
0.1kA 1kA 10kA

176 ABB SACE - Electrical devices

 5 Protection of human beings

5.6 IT System
As represented in Figure 1, the earth fault current in an IT system flows through
the line conductor capacitance to the power supply neutral point. For this reason,
the first earth fault is characterized by such an extremely low current value to
prevent the overcurrent protections from disconnecting; the deriving touch
voltage is very low.

Figure1: Earth fault in IT system

L1
L2
L3
Ik

C3 C2 C1

1SDC010037F0001
Ik

According to IEC 60364-4, the automatic disconnection of the circuit in case of

the first earth fault is not necessary only if the following condition is fulfilled:

Rt . I d U L
where:
Rt is the resistance of the earth electrode for exposed conductive parts [];
Id is the fault current, of the first fault of negligible impedance between
a phase conductor and an exposed conductive part [A];
UL is 50 V for ordinary locations (25 V for particular locations).

If this condition is fulfilled, after the first fault, the touch voltage value on the
exposed conductive parts is lower than 50 V, tolerable by the human body for
an indefinite time, as shown in the safety curve (see Chapter 5.1 General
aspects: effects of current on human beings).
In IT system installations, an insulation monitoring device shall be provided to

ABB SACE - Electrical devices 177

 5.6 IT System

5 Protection of human beings

indicate the occurrence of a first earth fault; in the event of a second fault, the
supply shall be disconnected according to the following modalities:

a) where exposed conductive parts are earthed in groups or individually,

the conditions for protection are the same as for TT systems (see
Chapter 5.4 TT system);
b) where exposed conductive parts are interconnected by a protective
conductor collectively earthed, the conditions of a TN system apply;
in particular, the following conditions shall be fulfilled:
if the neutral is not distributed:
U
Zs . r
2 Ia
if the neutral is distributed:

U
Z 's . 0
2 Ia
where
U0 is the rated voltage between phase and neutral [V];
Ur is the rated voltage between phases [V];
Zs is the impedance of the fault loop comprising the phase conductor and the
protective conductor of the circuit [];
Zs is the impedance of the fault loop comprising the neutral conductor and
the protective conductor of the circuit [];
Ia is the operating current of the protection device in the disconnecting time
specified in Table 1, or within 5 s for distribution circuits.

Table 1: Maximum disconnecting time in IT systems

Rated voltage disconnecting time [s]
U0/Ur [V] neutral not distributed neutral distributed
120/240 0.8 5
230/400 0.4 0.8
400/690 0.2 0.4
580/1000 0.1 0.2

IEC 60364-4 states that, if the requirements mentioned at point b) cannot be

fulfilled by using an overcurrent protective device, the protection of every supplied
load shall be provided by means of a residual current device.

The residual current device threshold shall be carefully chosen in order to avoid
unwanted tripping, due also to the particular path followed by the first fault
current through the line conductor capacitance to the power supply neutral
point (instead of the faulted line, another sound line with higher capacitance
could be affected by a higher fault current value).

178 ABB SACE - Electrical devices

 5 Protection of human beings

5.7 Residual current devices (RCDs)

Generalities on residual current circuit-breakers
The operating principle of the residual current release is basically the detection
of an earth fault current, by means of a toroid transformer which embraces all
the live conductors, included the neutral if distributed.

Figure 1: Operating principle of the residual current device

L N

1SDC010041F0001

In absence of an earth fault, the vectorial sum of the currents I is equal to zero;
in case of an earth fault if the I value exceeds the rated residual operating
current In, the circuit at the secondary side of the toroid sends a command
signal to a dedicated opening coil causing the tripping of the circuit-breaker.
A first classification of RCDs can be made according to the type of the fault
current they can detect:
- AC type: the tripping is ensured for residual sinusoidal alternating currents,
whether suddenly applied or slowly rising;
- A type: tripping is ensured for residual sinusoidal alternating currents and
residual pulsating direct currents, whether suddenly applied or slowly rising;
- B type: tripping is ensured for residual direct currents, for residual sinusoidal
alternating currents and residual pulsating direct currents, whether suddenly
applied or slowly rising.

Another classification referred to the operating time delay is:

- undelayed type;
- time delayed S-type.

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 5.7 Residual current devices

5 Protection of human beings

RCDs can be coupled, or not, with other devices; it is possible to distinguish
among:
- pure residual current circuit-breakers (RCCBs): they have only the residual
current release and can protect only against earth fault. They must be coupled
with thermomagnetic circuit-breakers or fuses, for the protection against
thermal and dynamical stresses;
- residual current circuit-breakers with overcurrent protection (RCBOs): they
are the combination of a thermomagnetic circuit-breaker and a RCD; for this
reason, they provide the protection against both overcurrents as well as earth
fault current;
- residual current circuit-breakers with external toroid: they are used in industrial
plants with high currents. They are composed by a release connected to an
external toroid with a winding for the detection of the residual current; in case
of earth fault, a signal commands the opening mechanism of a circuit-breaker
or a line contactor.
Given In the operating residual current, a very important parameter for residual
current devices is the residual non-operating current, which represents the
maximum value of the residual current which does not cause the circuit breaker
trip; it is equal to 0.5 In. Therefore, it is possible to conclude that:
- for I < 0.5In the RCD shall not operate;
- for 0.5In < I < In the RCD could operate;
- for I > In the RCD shall operate.
For the choice of the rated operating residual current, it is necessary to consider,
in addition to the coordination with the earthing system, also the whole of the
leakage currents in the plant; their vectorial sums on each phase shall not be
greater than 0.5In. in order to avoid unwanted tripping.

Discrimination between RCDs

The Standard IEC 60364-5-53 states that discrimination between residual
current protective devices installed in series may be required for service reasons,
particularly when safety is involved, to provide continuity of supply to the parts
of the installation not involved by the fault, if any. This discrimination can be
achieved by selecting and installing RCDs in order to provide the disconnection
from the supply by the RCD closest to the fault.
There are two types of discrimination between RCDs:
- horizontal discrimination: it provides the protection of each line by using a
dedicated residual current circuit-breaker; in this way, in case of earth fault,
only the faulted line is disconnected, since the other RCDs do not detect any
fault current. However, it is necessary to provide protective measures against
indirect contacts in the part of the switchboard and of the plant upstream the
RCD;
- vertical discrimination: it is realized by using RCDs connected in series.

Figure 2: Horizontal discrimination between RCDs

I 0.3 A I 0.3 A
I t 0.5 s I t 0.5 s

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 5.7 Residual current devices

5 Protection of human beings

Figure 3: Vertical discrimination between RCDs

I 1 A
I
t1s

I 0.3 A
I t 0.5 s

I I 0.03 A
t inst.

According to IEC 60364-5-53, to ensure discrimination between two residual

current protective devices in series, these devices shall satisfy both the following
conditions:
- the non-actuating time-current characteristic of the residual current protective
device located on the supply side (upstream) shall lie above the total operating
time-current characteristic of the residual current protective device located
on the load side (downstream);
- the rated residual operating current on the device located on the supply side
shall be higher than that of the residual current protective device located on
the load side.

The non-actuating time-current characteristic is the curve reporting the

maximum time value during which a residual current greater than the residual
non-operating current (equal to 0.5.In) involves the residual current circuit-
breaker without causing the tripping.
As a conclusion, discrimination between two RCDs connected in series can be
achieved:
- for S type residual current circuit-breakers, located on the supply side,
(complying with IEC 61008-1 and IEC 61009), time-delayed type, by choosing
general type circuit-breakers located downstream with In equal to one third
of In of the upstream ones;
- for electronic residual current releases (RC221/222/223, RCQ) by choosing
the upstream device with time and current thresholds directly greater than
the downstream device, keeping carefully into consideration the tolerances
(see Vol. 1, Chapter 2.3: Type of release).
For the protection against indirect contacts in distribution circuits in TT system,
the maximum disconnecting time at In shall not exceed 1 s (IEC 60364-4-41,
413.1)

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 5 Protection of human beings

5.8 Maximum protected length for the

protection of human beings
As described in the previous chapters, the Standards give indications about
the maximum disconnecting time for the protective devices, in order to avoid
pathophysiological effects for people touching live parts.
For the protection against indirect contact, it shall be verified that the circuit-
breaker trips within a time lower than the maximum time stated by the Standard;
this verification is carried out by comparing the minimum short-circuit current
of the exposed conductive part to be protected with the operating current
corresponding to the time stated by the Standard.
The minimum short-circuit current occurs when there is a short-circuit between
the phase and the protective conductors at the farthest point on the protected
conductor.
For the calculation of the minimum short-circuit current, an approximate method
can be used, assuming that:
- a 50 % increasing of the conductors resistance, with respect to the 20 C
value, is accepted, due to the overheating caused by the short-circuit
current;
- a 80 % reduction of the supply voltage is considered as effect of the
short-circuit current;
- the conductor reactance is considered only for cross sections larger
than 95 mm2.
The formula below is obtained by applying Ohms law between the protective
device and the fault point.

Legend of the symbols and constants of the formula:

- 0.8 is the coefficient representing the reduction of the voltage;
- 1.5 is the coefficient representing the increasing in the resistance;
- Ur is the rated voltage between phases;
- U0 is the rated voltage between phase and ground;
- S is the phase conductor cross section;
- SN is the neutral conductor cross section;
- SPE is the protection conductor cross section;
- is the conductor resistivity at 20 C;
- L is the length of the cable;
S n
- m= is the ratio between the total phase conductor cross section
SPE
(single phase conductor cross section S multiplied by n, number of
conductors in parallel) and the protective conductor cross section SPE
assuming they are made of the same conductor material;
SN n
- m1= is the ratio between the total neutral conductor cross section
SPE
(single neutral conductor cross section SN multiplied by n, number of
conductors in parallel) and the protective conductor cross section SPE
assuming they are made of the same conductor material;
- k1 is the correction factor which takes into account the reactance of
cables with cross section larger than 95 mm2, obtainable from the
following table:
Phase conductor cross section
[mm2] 120 150 185 240 300
k1 0.90 0.85 0.80 0.75 0.72

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 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

- k2 is the correction factor for conductors in parallel, obtainable by the
following formula:
n1
k2 = 4
n

where n is the number of conductor in parallel per phase;

- 1.2 is the magnetic threshold tolerance allowed by the Standard.

TN system
The formula for the evaluation of the minimum short circuit current is:
0.8 U 0 S
I k min = k1 k2
1.5 1.2 (1 + m) L
and consequently:

0.8 U 0 S
L= k1 k2
1.5 1.2 (1 + m) I k min

Dy
L1
L2
L3
N
PE

PE PE

Ik N L3 L2 L1
1SDC010043F0001

REN

IT system
The formulas below are valid when a second fault turns the IT system into a TN
system.
It is necessary to separately examine installations with neutral not distributed
and neutral distributed.

ABB SACE - Electrical devices 183

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

Neutral not distributed
When a second fault occurs, the formula becomes:
0.8 U r S
I k min = k1 k2
2 1.5 1.2 (1 + m) L
and consequently:
0.8 U r S
L= k1 k 2
2 1.5 1.2 (1 + m) I k min
Dy
L1
L2
L3

PE

PE PE
Z
Ik L3 L2 L1 Ik L3 L2 L1

1SDC010044F0001
PE

REN

Neutral distributed
Case A: three-phase circuits in IT system with neutral distributed
The formula is:
0.8 U 0 S
I k min = k1 k2
2 1.5 1.2 (1 + m) L
and consequently:
0.8 U 0 S
L= k1 k2
2 1.5 1.2 (1 + m) I k min

Case B: three-phase + neutral circuits in IT system with neutral distributed

The formula is:

0.8 U 0 SN
I k min = k1 k 2
2 1.5 1.2 (1 + m1) L
and consequently:
0.8 U 0 SN
L= k1 k 2
2 1.5 1.2 (1 + m1) I k min

184 ABB SACE - Electrical devices

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

Dy
L1
L2
L3
N
PE

PE PE
Z
Ik L3 L2 L1 Ik N L3 L2 L1

1SDC010045F0001
PE

REN A B

Note for the use of the tables

The tables showing the maximum protected length (MPL) have been defined
considering the following conditions:
- one cable per phase;
- rated voltage equal to 400 V (three-phase system);
- copper cables;
- neutral not distributed, for IT system only;
- protective conductor cross section according to Table 1:

Table 1: Protective conductor cross section

Phase conductor cross section S Protective conductor cross section SPE
[mm2] [mm2]
S 16 S
16 < S 35 16
S > 35 S/2
Note: phase and protective conductors having the same isolation and conductive materials

Whenever the S function (delayed short-circuit) of electronic releases is used

for the definition of the maximum protected length, it is necessary to verify that
the tripping time is lower than the time value reported in Chapter 5.5 Table 1 for
TN systems and in Chapter 5.6 Table 1 for IT systems.

For conditions different from the reference ones, the following correction factors
shall be applied.

ABB SACE - Electrical devices 185

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

Correction factors
Correction factor for cable in parallel per phase: the value of the maximum
protected length read in Table 2 (TN system) or Table 3 (IT system) shall be
multiplied by the following factor:

n 2 3 4 5 6 7 8
kp 2 2.7 3 3.2 3.3 3.4 3.5
n is the number of conductors in parallel per phase.

Correction factor for three-phase voltage different from 400 V: the value
of the maximum protected length read in Table 2 (TN system) or Table 3 (IT
system) shall be multiplied by the following factor:

voltage [V] 230 400 440 500 690

kV 0.58 1 1.1 1.25 1.73

For 230 V single-phase systems, no correction factor is necessary.

Correction factor for aluminium cables: the value of the maximum protected
length read in Table 2 (TN system) or Table 3 (IT system) shall be multiplied by
the following factor:

kAl 0.64

Correction factor for protective conductor cross section SPE different

from the cross sections stated in Table 1: the value of the maximum
protected length shall be multiplied by the coefficient corresponding to the
phase conductor cross section and to the ratio between the protective conductor
(PE) and the phase cross sections:

SPE/S 0.5 0.55 0.6 0.66 0.75 0.87 1 1.25 1.5 2

S kPE
16 mm2 0.67 0.71 0.75 0.80 0.86 0.93 1.00 1.11 1.20 1.33
25 mm2 0.85 0.91 0.96 1.02 1.10 1.19 1.28 1.42 1.54 1.71
35 mm2 1.06 1.13 1.20 1.27 1.37 1.48 1.59 1.77 1.91 2.13
>35 mm2 1.00 1.06 1.13 1.2 1.29 1.39 1.5 1.67 1.8 2.00

Correction factor for neutral distributed in IT system (for Table 3 only):

the value of the maximum protected length shall be multiplied by 0.58.

186 ABB SACE - Electrical devices

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

TN system MPL
by MCB Table 2.1: Curve Z

CURVE Z Z Z Z Z Z Z Z Z
In 10 13 16 20 25 32 40 50 63
I3 30 39 48 60 75 96 120 150 189
S SPE
1.5 1.5 173 133 108 86 69 54 43
2.5 2.5 288 221 180 144 115 90 72 58 45
4 4 461 354 288 231 185 144 115 92 72
6 6 692 532 432 346 277 216 173 138 108
10 10 1153 886 721 577 461 360 288 231 180
16 16 1845 1419 1153 923 738 577 461 369 288
25 16 2250 1730 1406 1125 900 703 563 450 352

Table 2.2: Curve B

CURVE B B B B B B B B B B B B B
In 6 8 10 13 16 20 25 32 40 50 63 80 100
I3 30 40 50 65 80 100 125 160 200 250 315 400 500
S SPE
1.5 1.5 173 130 104 80 65 52 42 32 26
2.5 2.5 288 216 173 133 108 86 69 54 43 35 27
4 4 461 346 277 213 173 138 111 86 69 55 44 35 28
6 6 692 519 415 319 259 208 166 130 104 83 66 52 42
10 10 1153 865 692 532 432 346 277 216 173 138 110 86 69
16 16 1845 1384 1107 852 692 554 443 346 277 221 176 138 111
25 16 2250 1688 1350 1039 844 675 540 422 338 270 214 169 135
35 16 190 152

Table 2.3: Curve C

CURVE C C C C C C C C C C C C C C C C
In 3 4 6 8 10 13 16 20 25 32 40 50 63 80 100 125
I3 30 40 60 80 100 130 160 200 250 320 400 500 630 800 1000 1250
S SPE
1.5 1.5 173 130 86 65 52 40 32 26 21 16 13
2.5 2.5 288 216 144 108 86 67 54 43 35 27 22 17 14
4 4 461 346 231 173 138 106 86 69 55 43 35 28 22 17 14 11
6 6 692 519 346 259 208 160 130 104 83 65 52 42 33 26 21 17
10 10 1153 865 577 432 346 266 216 173 138 108 86 69 55 43 35 28
16 16 1845 1384 923 692 554 426 346 277 221 173 138 111 88 69 55 44
25 16 2250 1688 1125 844 675 519 422 338 270 211 169 135 107 84 68 54
35 16 95 76 61

ABB SACE - Electrical devices 187

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

TN system MPL
by MCB Table 2.4: Curve K

CURVE K K K K K K K K K K K K K K K K K K K K K K
In 2 3 4 4.2 5.8 6 8 10 11 13 15 16 20 25 26 32 37 40 41 45 50 63
I3 28 42 56 59 81 84 112 140 154 182 210 224 280 350 364 448 518 560 574 630 700 882
S SPE
1.5 1.5 185 123 92 88 64 62 46 37 34 28 25 23 18 15 14 12 10 9
2.5 2.5 308 205 154 146 106 103 77 62 56 47 41 38 31 25 24 19 17 15 15 14
4 4 492 328 246 234 170 164 123 98 89 76 66 62 49 39 38 31 27 25 24 22 20 16
6 6 738 492 369 350 255 246 185 148 134 114 98 92 74 59 57 46 40 37 36 33 30 23
10 10 1231 820 615 584 425 410 308 246 224 189 164 154 123 98 95 77 67 62 60 55 49 39
16 16 1969 1313 984 934 681 656 492 394 358 303 263 246 197 158 151 123 106 98 96 88 79 63
25 16 2401 1601 1201 1140 830 800 600 480 437 369 320 300 240 192 185 150 130 120 117 107 96 76

Table 2.5: Curve D

CURVE D D D D D D D D D D D D D D D D
In 2 3 4 6 8 10 13 16 20 25 32 40 50 63 80 100
I3 40 60 80 120 160 200 260 320 400 500 640 800 1000 1260 1600 2000
S SPE
1.5 1.5 130 86 65 43 32 26 20 16 13 10 8 6
2.5 2.5 216 144 108 72 54 43 33 27 22 17 14 11 9 7
4 4 346 231 173 115 86 69 53 43 35 28 22 17 14 11 9 7
6 6 519 346 259 173 130 104 80 65 52 42 32 26 21 16 13 10
10 10 865 577 432 288 216 173 133 108 86 69 54 43 35 27 22 17
16 16 1384 923 692 461 346 277 213 173 138 111 86 69 55 44 35 28
25 16 1688 1125 844 563 422 338 260 211 169 135 105 84 68 54 42 34
35 16 47 38

188 ABB SACE - Electrical devices

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

TN system MPL
by MCCB Table 2.6: TmaxT1 TMD

T1 T1 T1 T1 T1 T1
In 50 63 80 100 125 160
I3 500 A 10 In 10 In 10 In 10 In 10 In
S SPE
1.5 1.5 6
2.5 2.5 10
4 4 15 12 10 8 6
6 6 23 18 14 12 9 7
10 10 38 31 24 19 15 12
16 16 62 49 38 31 25 19
25 16 75 60 47 38 30 23
35 16 84 67 53 42 34 26
50 25 128 102 80 64 51 40
70 35 179 142 112 90 72 56
95 50 252 200 157 126 101 79

Table 2.7: Tmax T2 TMD

T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2
In 1.6 2 2.5 3.2 4 5 6.3 8 10 12.5 1650 63 80 100 125 160
I3 10 In 10 In 10 In 10 In 10 In 10 In 10 In 10 In 10 In 10 In 500 A 10 In 10 In 10 In 10 In 10 In
S SPE
1.5 1.5 246 197 157 123 98 79 62 49 39 31 8
2.5 2.5 410 328 262 205 164 131 104 82 66 52 13
4 4 655 524 419 328 262 210 166 131 105 84 21 17 13 10 8
6 6 983 786 629 491 393 315 250 197 157 126 31 25 20 16 13 10
10 10 1638 1311 1048 819 655 524 416 328 262 210 52 42 33 26 21 16
16 16 2621 2097 1677 1311 1048 839 666 524 419 335 84 67 52 42 34 26
25 16 1598 1279 1023 812 639 511 409 102 81 64 51 41 32
35 16 1151 914 720 576 460 115 91 72 58 46 36
50 25 1092 874 699 175 139 109 87 70 55
70 35 979 245 194 153 122 98 76
95 50 343 273 215 172 137 107
120 70 417 331 261 209 167 130
150 95 518 411 324 259 207 162
185 95 526 418 329 263 211 165

ABB SACE - Electrical devices 189

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

TN system MPL
by MCCB Table 2.8: Tmax T3 TMD
T3 T3 T3 T3 T3 T3 T3
In 63 80 100 125 160 200 250
I3 10 In 10 In 10 In 10 In 10 In 10 In 10 In
S SPE
4 4 17 13 10 8
6 6 25 20 16 13 10 8
10 10 42 33 26 21 16 13 10
16 16 67 52 42 34 26 21 17
25 16 81 64 51 41 32 26 20
35 16 91 72 58 46 36 29 23
50 25 139 109 87 70 55 44 35
70 35 194 153 122 98 76 61 49
95 50 273 215 172 137 107 86 69
120 70 331 261 209 167 130 104 83
150 95 411 324 259 207 162 130 104
185 95 418 329 263 211 165 132 105
240 120 499 393 315 252 197 157 126

Table 2.9: Tmax T4 TMD/TMA

T4 T4 T4 T4 T4 T4 T4 T4 T4 T4
In 20 32 50 80 100 125 160 200 250 320
I3 320 A 10 In 10 In 5...10 In 5...10 In 5...10 In 5...10 In 5...10 In 5...10 In 5...10 In
S SPE
1.5 1.5 14 14 9 115 94 73 53 42 32 31
2.5 2.5 23 23 14 189 147 126 95 74 63 52
4 4 36 36 23 2914 2312 189 147 126 95 74
6 6 54 54 35 4322 3517 2814 2211 179 147 115
10 10 90 90 58 7236 5829 4623 3618 2914 2312 189
16 16 144 144 92 11558 9246 7437 5829 4623 3718 2914
25 16 176 176 113 14170 11356 9045 7035 5628 4523 3518
35 16 198 198 127 15879 12763 10151 7940 6332 5125 4020
50 25 300 300 192 240120 19296 15477 12060 9648 7738 6030
70 35 420 420 269 336168 269135 215108 16884 13567 10854 8442
95 50 590 590 378 472236 378189 302151 236118 18994 15176 11859
120 70 717 717 459 574287 459229 367184 287143 229115 18492 14372
150 95 891 891 570 713356 570285 456228 356178 285143 228114 17889
185 95 905 905 579 724362 579290 463232 362181 290145 232116 18190
240 120 1081 1081 692 865432 692346 554277 432216 346173 277138 216108
300 150 1297 1297 830 1038519 830415 664332 519259 415208 332166 259130

190 ABB SACE - Electrical devices

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

TN system MPL
by MCCB Table 2.10: Tmax T5 TMA
T5 T5 T5 T5
In 320 400 500 630
I3 5...10 In 5...10 In 5...10 In 5...10 In
S SPE
1,5 1,5 31 21 21 11
2,5 2,5 52 42 31 21
4 4 74 63 52 42
6 6 115 94 73 53
10 10 189 147 126 95
16 16 2914 2312 189 157
25 16 3518 2814 2311 189
35 16 4020 3216 2513 2010
50 25 6030 4824 3819 3115
70 35 8442 6734 5427 4321
95 50 11859 9447 7638 6030
120 70 14372 11557 9246 7336
150 95 17889 14371 11457 9145
185 95 18190 14572 11658 9246
240 120 216108 17386 13869 11055
300 150 259130 208104 16683 13266

Table 2.11: Tmax T2 with PR221 DS-LS

T2 T2 T2 T2 T2
In 10 25 63 100 160
I3 5.5 In 5.5 In 5.5 In 5.5 In 5.5 In
S SPE
1.5 1.5 79 31 12
2.5 2.5 131 52 21
4 4 210 84 33 21
6 6 315 126 50 31 20
10 10 524 210 83 52 33
16 16 839 335 133 84 52
25 16 1023 409 162 102 64
35 16 1151 460 183 115 72
50 25 1747 699 277 175 109
70 35 2446 979 388 245 153
95 50 3434 1374 545 343 215
120 70 4172 1669 662 417 261
150 95 5183 2073 823 518 324
185 95 5265 2106 836 526 329
Note: if the setting of function I is different from the reference value (5.5) the value of the
MPL shall be multiplied by the ratio between the reference value and the set value.

ABB SACE - Electrical devices 191

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

TN system MPL
by MCCB Table 2.12: Tmax T4-T5 with PR221 - PR222

T4 T4 T4 T4 T5 T5 T5
In 100 160 250 320 320 400 630
I3 6.5 In 6.5 In 6.5 In 6.5 In 6.5 In 6.5 In 6.5 In
S SPE
1,5 1,5
2,5 2,5
4 4
6 6 29 18
10 10 48 30 19
16 16 77 48 31 24 24 19
25 16 94 59 38 30 30 24 15
35 16 106 66 43 33 33 27 17
50 25 161 101 65 50 50 40 26
70 35 226 141 90 71 71 56 36
95 50 317 198 127 99 99 79 50
120 70 385 241 154 120 120 96 61
150 95 478 299 191 150 150 120 76
185 95 486 304 194 152 152 121 77
240 120 581 363 232 181 181 145 92
300 150 697 435 279 218 218 174 111
Note: if the setting of function I is different from the reference value (6.5) the value of the
MPL shall be multiplied by the ratio between the reference value and the set value.

Table 2.13: SACE Isomax S6S8 with PR211- PR212

S6 S7 S7 S7 S8 S8 S8 S8
In 800 1000 1250 1600 1600 2000 2500 3200
I3 6 In 6 In 6 In 6 In 6 In 6 In 6 In 6 In
S SPE

2.5 2.5
4 4
6 6
10 10
16 16
25 16
35 16
50 25 20
70 35 28 22 18 14 14
95 50 39 31 25 20 20 16 13 10
120 70 48 38 31 24 24 19 15 12
150 95 59 48 38 30 30 24 19 15
185 95 60 48 39 30 30 24 19 15
240 120 72 58 46 36 36 29 23 18
300 150 86 69 55 43 43 35 28 22
Note: if the setting of function S or I is different from the reference value (6) the MPL
value shall be multiplied by the ratio between the reference value and the set value.
Besides, using function S the MPL shall be multiplied by 1.1.

192 ABB SACE - Electrical devices

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

IT system MPL
by MCB Table 3.1: Curve Z

CURVE Z Z Z Z Z Z Z Z Z Z
In 8 10 13 16 20 25 32 40 50 63
I3 30 30 39 48 60 75 96 120 150 189
S SPE
1.5 1.5 150 150 115 94 75 60 47 37
2.5 2.5 250 250 192 156 125 100 78 62 50 40
4 4 400 400 307 250 200 160 125 100 80 63
6 6 599 599 461 375 300 240 187 150 120 95
10 10 999 999 768 624 499 400 312 250 200 159
16 16 1598 1598 1229 999 799 639 499 400 320 254
25 16 1949 1949 1499 1218 974 780 609 487 390 309

Table 3.2: Curve B

CURVE B B B B B B B B B B B B B
In 6 8 10 13 16 20 25 32 40 50 63 80 100
I3 30 40 50 65 80 100 125 160 200 250 315 400 500
S SPE
1.5 1.5 150 112 90 69 56 45 36 28 22
2.5 2.5 250 187 150 115 94 75 60 47 37 30 24
4 4 400 300 240 184 150 120 96 75 60 48 38 30 24
6 6 599 449 360 277 225 180 144 112 90 72 57 45 36
10 10 999 749 599 461 375 300 240 187 150 120 95 75 60
16 16 1598 1199 959 738 599 479 384 300 240 192 152 120 96
25 16 1949 1462 1169 899 731 585 468 365 292 234 186 146 117
35 16 165 132

Table 3.3: Curve C

CURVE C C C C C C C C C C C C C C C C
In 3 4 6 8 10 13 16 20 25 32 40 50 63 80 100 125
I3 30 40 60 80 100 130 160 200 250 320 400 500 630 800 1000 1250
S SPE
1.5 1.5 150 112 75 56 45 35 28 22 18 14 11
2.5 2.5 250 187 125 94 75 58 47 37 30 23 19 15 12
4 4 400 300 200 150 120 92 75 60 48 37 30 24 19 15 12 10
6 6 599 449 300 225 180 138 112 90 72 56 45 36 29 22 18 14
10 10 999 749 499 375 300 230 187 150 120 94 75 60 48 37 30 24
16 16 1598 1199 799 599 479 369 300 240 192 150 120 96 76 60 48 38
25 16 1949 1462 974 731 585 450 365 292 234 183 146 117 93 73 58 47
35 16 82 66 53

ABB SACE - Electrical devices 193

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

IT system MPL
by MCB Table 3.4: Curve K
CURVE K K K K K K K K K K K K K K K K K K K K K K
In 2 3 4 4.2 5.8 6 8 10 11 13 15 16 20 25 26 32 37 40 41 45 50 63
I3 28 42 56 59 81 84 112 140 154 182 210 224 280 350 364 448 518 560 574 630 700 882
S SPE
1.5 1.5 161 107 80 76 55 54 40 32 29 25 21 20 16 13 12 10 9 8
2.5 2.5 268 178 134 127 92 89 67 54 49 41 36 33 27 21 21 17 14 13 13 12
4 4 428 285 214 204 148 143 107 86 78 66 57 54 43 34 33 27 23 21 21 19 17 14
6 6 642 428 321 306 221 214 161 128 117 99 86 80 64 51 49 40 35 32 31 29 26 20
10 10 1070 713 535 510 369 357 268 214 195 165 143 134 107 86 82 67 58 54 52 48 43 34
16 16 1712 1141 856 815 590 571 428 342 311 263 228 214 171 137 132 107 93 86 84 76 68 54
25 16 2088 1392 1044 994 720 696 522 418 380 321 278 261 209 167 161 130 113 104 102 93 84 66

Table 3.5: Curve D

CURVE D D D D D D D D D D D D D D D D
In 2 3 4 6 8 10 13 16 20 25 32 40 50 63 80 100
I3 40 60 80 120 160 200 260 320 400 500 640 800 1000 1260 1600 2000
S SPE
1.5 1.5 112 75 56 37 28 22 17 14 11 9 7 6
2.5 2.5 187 125 94 62 47 37 29 23 19 15 12 9 7 6
4 4 300 200 150 100 75 60 46 37 30 24 19 15 12 10 7 6
6 6 449 300 225 150 112 90 69 56 45 36 28 22 18 14 11 9
10 10 749 499 375 250 187 150 115 94 75 60 47 37 30 24 19 15
16 16 1199 799 599 400 300 240 184 150 120 96 75 60 48 38 30 24
25 16 1462 974 731 487 365 292 225 183 146 117 91 73 58 46 37 29
35 41 33

194 ABB SACE - Electrical devices

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

IT system MPL
by MCCB Table 3.6: Tmax T1 TMD
T1 T1 T1 T1 T1 T1
In 50 63 80 100 125 160
I3 500 A 10 In 10 In 10 In 10 In 10 In
S SPE
1.5 1.5 5
2.5 2.5 8
4 4 13 11 8 7 5
6 6 20 16 12 10 8 6
10 10 33 26 21 17 13 10
16 16 53 42 33 27 21 17
25 16 65 52 41 32 26 20
35 16 73 58 46 37 29 23
50 25 111 88 69 55 44 35
70 35 155 123 97 78 62 49
95 50 218 173 136 109 87 68

Table 3.7: Tmax T2 TMD

T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2 T2
In 1.6 2 2.5 3.2 4 5 6.3 8 10 12.5 1650 63 80 100 125 160
I3 10 In 10 In 10 In 10 In 10 In 10 In 10 In 10 In 10 In 10 In 500 A 10 In 10 In 10 In 10 In 10 In
S SPE
1.5 1.5 213 170 136 106 85 68 54 43 34 27 7
2.5 2.5 355 284 227 177 142 113 90 71 57 45 11
4 4 567 454 363 284 227 182 144 113 91 73 18 14 11 9 7
6 6 851 681 545 426 340 272 216 170 136 109 27 22 17 14 11 9
10 10 1419 1135 908 709 567 454 360 284 227 182 45 36 28 23 18 14
16 16 2270 1816 1453 1135 908 726 576 454 363 291 73 58 45 36 29 23
25 16 1384 1107 886 703 554 443 354 89 70 55 44 35 28
35 16 997 791 623 498 399 100 79 62 50 40 31
50 25 946 757 605 151 120 95 76 61 47
70 35 847 212 168 132 106 85 66
95 50 297 236 186 149 119 93
120 70 361 287 226 181 145 113
150 95 449 356 281 224 180 140
185 95 456 362 285 228 182 142

ABB SACE - Electrical devices 195

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

IT system MPL
by MCCB Table 3.8: Tmax T3 TMD
T3 T3 T3 T3 T3 T3 T3
In 63 80 100 125 160 200 250
I3 10 In 10 In 10 In 10 In 10 In 10 In 10 In
S SPE
4 4 14 11 9 7
6 6 22 17 14 11 9 7
10 10 36 28 23 18 14 11 9
16 16 58 45 36 29 23 18 15
25 16 70 55 44 35 28 22 18
35 16 79 62 50 40 31 25 20
50 25 120 95 76 61 47 38 30
70 35 168 132 106 85 66 53 42
95 50 236 186 149 119 93 74 59
120 70 287 226 181 145 113 90 72
150 95 356 281 224 180 140 112 90
185 95 362 285 228 182 142 114 91
240 120 432 340 272 218 170 136 109

Table 3.9: Tmax T4 TMD/TMA

T4 T4 T4 T4 T4 T4 T4 T4 T4 T4
In 20 32 50 80 100 125 160 200 250 320
I3 320 A 10 In 10 In 5...10 In 5...10 In 5...10 In 5...10 In 5...10 In 5...10 In 5...10 In
S SPE
1,5 1,5 12 12 7 95 74 63 52 42 31 21
2,5 2,5 20 20 12 168 126 105 84 63 52 42
4 4 31 31 20 2512 2010 168 126 105 84 63
6 6 47 47 30 3719 3015 2412 199 157 126 95
10 10 78 78 50 6231 5025 4020 3116 2512 2010 168
16 16 125 125 80 10050 8040 6432 5025 4020 3216 2512
25 16 152 152 97 12261 9749 7839 6130 4924 3919 3015
35 16 171 171 110 13769 11055 8844 6934 5527 4422 3417
50 25 260 260 166 208104 16683 13367 10452 8342 6733 5226
70 35 364 364 233 291146 233117 18693 14673 11758 9347 7336
95 50 511 511 327 409204 327164 262131 204102 16482 13165 10251
120 70 621 621 397 497248 397199 318159 248124 19999 15979 12462
150 95 772 772 494 617309 494247 395198 309154 247123 19899 15477
185 95 784 784 502 627313 502251 401201 313157 251125 201100 15778
240 120 936 936 599 749375 599300 479240 375187 300150 240120 18794
300 150 1124 1124 719 899449 719360 575288 449225 360180 288144 225112

196 ABB SACE - Electrical devices

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

IT system MPL
by MCCB Table 3.10: Tmax T5 TMA
T5 T5 T5 T5
In 320 400 500 630
I3 5...10 In 5...10 In 5...10 In 5...10 In
S SPE
1,5 1,5 21 21 11 11
2,5 2,5 42 32 21 21
4 4 63 52 42 32
6 6 95 74 63 52
10 10 168 126 105 84
16 16 2512 2010 168 136
25 16 3015 2412 1910 158
35 16 3417 2714 2211 179
50 25 5226 4221 3317 2613
70 35 7336 5829 4723 3718
95 50 10251 8241 6533 5226
120 70 12462 9950 7940 6332
150 95 15477 12362 9949 7839
185 95 15778 12563 10050 8040
240 120 18794 15075 12060 9548
300 150 225112 18090 14472 11457

Table 3.11: Tmax T2 with PR221DS-LS

T2 T2 T2 T2 T2
In 10 25 63 100 160
I3 5.5 In 5.5 In 5.5 In 5.5 In 5.5 In
S SPE
1.5 1.5 68 27 11
2.5 2.5 113 45 18
4 4 182 73 29 18
6 6 272 109 43 27 17
10 10 454 182 72 45 28
16 16 726 291 115 73 45
25 16 886 354 141 89 55
35 16 997 399 158 100 62
50 25 1513 605 240 151 95
70 35 2119 847 336 212 132
95 50 2974 1190 472 297 186
120 70 3613 1445 573 361 226
150 95 4489 1796 713 449 281
185 95 4559 1824 724 456 285

Note: if the setting of function I is different from the reference value (5.5) the MPL value
shall be multiplied by the ratio between the reference value and the set value.

ABB SACE - Electrical devices 197

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

IT system MPL Table 3.12: Tmax T4-T5 with PR221-PR222
by MCCB
T4 T4 T4 T4 T5 T5 T5
In 100 160 250 320 320 400 630
I3 6.5 In 6.5 In 6.5 In 6.5 In 6.5 In 6.5 In 6.5 In
S SPE
1,5 1,5
2,5 2,5
4 4
6 6 25 16
10 10 42 26 17
16 16 67 42 27 21 21 17
25 16 82 51 33 26 26 20 13
35 16 92 58 37 29 29 23 15
50 25 140 87 56 44 44 35 22
70 35 196 122 78 61 61 49 31
95 50 275 172 110 86 86 69 44
120 70 333 208 133 104 104 83 53
150 95 414 259 166 129 129 104 66
185 95 421 263 168 132 132 105 67
240 120 503 314 201 157 157 126 80
300 150 603 377 241 189 189 151 96

Note: if the setting of function I is different from the reference value (6.5) the value of the
MPL shall be multiplied by the ratio between the reference value and the set value.

198 ABB SACE - Electrical devices

 5.8 Maximum protected length for the protection of human beings

5 Protection of human beings

IT system MPL Table 3.13: SACE Isomax S6-S8 with PR211-212
by MCCB
S6 S7 S7 S7 S8 S8 S8 S8
In 800 1000 1250 1600 1600 2000 2500 3200
I3 6 In 6 In 6 In 6 In 6 In 6 In 6 In 6 In
S SPE
2.5 2.5
4 4
6 6
10 10
16 16
25 16
35 16
50 25 17
70 35 24 19 16 12 12
95 50 34 27 22 17 17 14 11 9
120 70 41 33 26 21 21 17 13 10
150 95 51 41 33 26 26 21 16 13
185 95 52 42 33 26 26 21 17 13
240 120 62 50 40 31 31 25 20 16
300 150 75 60 48 37 37 30 24 19
Note: if the setting of function S or I is different from the reference value (6) the MPL value
shall be multiplied by the ratio between the reference value and the set value. Besides,
using function S, the MPL shall be multiplied by 1.1.

ABB SACE - Electrical devices 199

 Annex A: Calculation tools

A.1 Slide rules

These slide rules represent a valid instrument for a quick and approximate
dimensioning of electrical plants.
All the given information is connected to some general reference conditions;
the calculation methods and the data reported are gathered from the IEC
Standards in force and from plant engineering practice. The instruction manual
enclosed with the slide rules offers different examples and tables showing the
correction coefficients necessary to extend the general reference conditions to
those actually required.

These two-sided slide rules are available in four different colors, easily identified
by subject:
- yellow slide rule: cable sizing;
- orange slide rule: cable verification and protection;
- green slide rule: protection coordination;
- blue slide rule: motor and transformer protection.

200 ABB SACE - Electrical devices

 A.1 Slide rules

Annex A: Calculation tools

Yellow slide rule: cable sizing

Side
Definition of the current carrying capacity, impedance and voltage drop of cables.

Side
Calculation of the short-circuit current for three-phase fault on the load side of
a cable line with known cross section and length.
In addition, a diagram for the calculation of the short-circuit current on the load
side of elements with known impedance.

1SDC008059F0001

ABB SACE - Electrical devices 201

 A.1 Slide rules

Annex A: Calculation tools

Orange slide rule: cable verification and protection
Side
Verification of cable protection against indirect contact and short-circuit with
ABB SACE MCCBs (moulded-case circuit-breakers).

Side
Verification of cable protection against indirect contact and short-circuit with
ABB MCBs (modular circuit-breakers).

1SDC008060F0001

202 ABB SACE - Electrical devices

 A.1 Slide rules

Annex A: Calculation tools

Green slide rule: protection coordination
Side
Selection of the circuit-breakers when back-up protection is provided.

Side
Definition of the discrimination limit current for the combination of two circuit-
breakers in series.

1SDC008061F0001

ABB SACE - Electrical devices 203

 A.1 Slide rules

Annex A: Calculation tools

Blue slide rule: motor and transformer protection
Side
Selection and coordination of the protection devices for the motor starter, DOL
start-up (coordination type 2 in compliance with the Standard IEC 60947-4-1).

Side
Sizing of a transformer feeder.
In addition, a diagram for the calculation of the short-circuit current on the load
side of transformers with known rated power.

1SDC008062F0001

204 ABB SACE - Electrical devices

 A.2 DOCWin

Annex A: Calculation tools

A.2 DOCWin
DOCWin is a software for the dimensioning of electrical networks, with low or
medium voltage supply.
Networks can be completely calculated through simple operations starting from
the definition of the single-line diagram and thanks to the drawing functions
provided by an integrated CAD software.

Drawing and definition of networks

Creation of the single-line diagram, with no limits to the network complexity.
Meshed networks can also be managed.
The diagram can be divided into many pages.
The program controls the coherence of drawings in real time.
It is possible to enter and modify the data of the objects which form the
network by using a table.
It is possible to define different network configurations by specifying the status
(open/closed) of the operating and protective devices.

Supplies
There are no pre-defined limits: the software manages MV and LV power
supplies and generators, MV/LV and LV/LV transformers, with two or three
windings, with or without voltage regulator, according to the requirements.

Network calculation
Load Flow calculation using the Newton-Raphson method. The software can
manage networks with multiple slacks and unbalances due to single- or two-
phase loads. Magnitude and phase shift of the node voltage and of the branch
current are completely defined for each point of the network, for both MV as
well as LV.
Calculation of the active and reactive power required by each single power
source.

ABB SACE - Electrical devices 205

 A.2 DOCWIN

Annex A: Calculation tools

Management of local (motors) and centralized power factor correction with
capacitor banks.
Management of the demand factor for each single node of the network and
of the utilization factor on the loads.
Short-circuit current calculation for three-phase, phase-to-phase, phase-to-
neutral, phase-to-ground faults. The calculation is also carried out for MV
sections, in compliance with the Standards IEC 60909-1, IEC 61363-1 (naval
installations) or with the method of symmetric components, taking into account
also the time-variance contribution of rotary machines (generators and motors).
Calculation of switchboard overtemperature in compliance with Standard IEC
60890. The power dissipated by the single apparatus is automatically derived
by the data files of the software, and can be considered as a function of the
rated current or of the load current.

Cable line sizing

Cable line sizing according to thermal criteria in compliance with the following
Standards: CEI 64-8 (tables CEI UNEL 35024-35026), IEC 60364, VDE 298-
4, NFC 15-100, IEC 60092 (naval installations) and IEC 60890.
Possibility of setting, as additional calculation criterion, the economic criteria
stated in the Standard IEC 60827-3-2.
Possibility of setting, as additional calculation criterion, the maximum allowed
voltage drop.
Automatic sizing of busbar trunking system.
Sizing and check on the dynamic withstand of busbars in compliance with
the Standard IEC 60865.

Curves and verifications

Representation of:
- time / current curves (I-t),
- current / let-through energy curves (I-I2t),
- current limiting curves (peak): visual check of the effects of the settings on the
trip characteristics of protection devices.

206 ABB SACE - Electrical devices

 A.2 DOCWin

Annex A: Calculation tools

Representation of the curves of circuit-breakers, cables, transformers, motors
and generators.
Possibility of entering the curve of the utility and of the MV components point
by point, to verify the tripping discrimination of protection devices.
Verification of the maximum voltage drop at each load.
Verification of the protection devices, with control over the setting parameters
of the adjustable releases (both thermomagnetic as well as electronic).

Selection of operating and protection devices

Automatic selection of protection devices (circuit-breakers and fuses)
Automatic selection of operating devices (contactors and switch disconnectors)
Discrimination and back-up managed as selection criteria, with discrimination
level adjustable for each circuit-breaker combination.

Discrimination and back-up verification also through quick access to

coordination tables.

ABB SACE - Electrical devices 207

 A.2 DOCWIN

Annex A: Calculation tools

Motor coordination management through quick access to ABB tables.

Printouts
Single-line diagram, curves and reports of the single components of the
network can be printed by any printer supported by the hardware
configuration.
All information can be exported in the most common formats of data exchange.
All print modes can be customized.

208 ABB SACE - Electrical devices

 Annex B: Calculation of load current Ib
Generic loads
The formula for the calculation of the load current of a generic load is:
P
Ib =
k U r cos
where:
P is the active power [W];
k is a coefficient which has the value:
- 1 for single-phase systems or for direct current systems;
- for three-phase systems;
Ur is the rated voltage [V] (for three-phase systems it is the line voltage, for
single-phase systems it is the phase voltage);
cos is the power factor.

Table 1 allows the load current to be determined for some power values
according to the rated voltage. The table has been calculated considering cos
to be equal to 0.9; for different power factors, the value from Table 1 must be
multiplied by the coefficient given in Table 2 corresponding to the actual value
of the power factor (cosact).

Table 1: Load current for three-phase systems with cos = 0.9

Ur [V]
230 400 415 440 500 600 690
P [kW] Ib [A]
0.03 0.08 0.05 0.05 0.04 0.04 0.03 0.03
0.04 0.11 0.06 0.06 0.06 0.05 0.04 0.04
0.06 0.17 0.10 0.09 0.09 0.08 0.06 0.06
0.1 0.28 0.16 0.15 0.15 0.13 0.11 0.09
0.2 0.56 0.32 0.31 0.29 0.26 0.21 0.19
0.5 1.39 0.80 0.77 0.73 0.64 0.53 0.46
1 2.79 1.60 1.55 1.46 1.28 1.07 0.93
2 5.58 3.21 3.09 2.92 2.57 2.14 1.86
5 13.95 8.02 7.73 7.29 6.42 5.35 4.65
10 27.89 16.04 15.46 14.58 12.83 10.69 9.30
20 55.78 32.08 30.92 29.16 25.66 21.38 18.59
30 83.67 48.11 46.37 43.74 38.49 32.08 27.89
40 111.57 64.15 61.83 58.32 51.32 42.77 37.19
50 139.46 80.19 77.29 72.90 64.15 53.46 46.49
60 167.35 96.23 92.75 87.48 76.98 64.15 55.78
70 195.24 112.26 108.20 102.06 89.81 74.84 65.08
80 223.13 128.30 123.66 116.64 102.64 85.53 74.38
90 251.02 144.34 139.12 131.22 115.47 96.23 83.67
100 278.91 160.38 154.58 145.80 128.30 106.92 92.97
110 306.80 176.41 170.04 160.38 141.13 117.61 102.27
120 334.70 192.45 185.49 174.95 153.96 128.30 111.57
130 362.59 208.49 200.95 189.53 166.79 138.99 120.86
140 390.48 224.53 216.41 204.11 179.62 149.68 130.16
150 418.37 240.56 231.87 218.69 192.45 160.38 139.46
200 557.83 320.75 309.16 291.59 256.60 213.83 185.94

ABB SACE - Electrical devices 209

 Calculation of load curremt Ib

Annex B: Calculation of load current Ib

Ur [V]
230 400 415 440 500 600 690
P [kW] Ib[A]
250 697.28 400.94 386.45 364.49 320.75 267.29 232.43
300 836.74 481.13 463.74 437.39 384.90 320.75 278.91
350 976.20 561.31 541.02 510.28 449.05 374.21 325.40
400 1115.65 641.50 618.31 583.18 513.20 427.67 371.88
450 1255.11 721.69 695.60 656.08 577.35 481.13 418.37
500 1394.57 801.88 772.89 728.98 641.50 534.58 464.86
550 1534.02 882.06 850.18 801.88 705.65 588.04 511.34
600 1673.48 962.25 927.47 874.77 769.80 641.50 557.83
650 1812.94 1042.44 1004.76 947.67 833.95 694.96 604.31
700 1952.39 1122.63 1082.05 1020.57 898.10 748.42 650.80
750 2091.85 1202.81 1159.34 1093.47 962.25 801.88 697.28
800 2231.31 1283.00 1236.63 1166.36 1026.40 855.33 743.77
850 2370.76 1363.19 1313.92 1239.26 1090.55 908.79 790.25
900 2510.22 1443.38 1391.21 1312.16 1154.70 962.25 836.74
950 2649.68 1523.56 1468.49 1385.06 1218.85 1015.71 883.23
1000 2789.13 1603.75 1545.78 1457.96 1283.00 1069.17 929.71

Table 2: Correction factors for load current with cos other than 0.9

cosact 1 0.95 0.9 0.85 0.8 0.75 0.7

kcos* 0.9 0.947 1 1.059 1.125 1.2 1.286

0.9
*
For cosact values not present in the table, kcos =
cos act
Table 3 allows the load current to be determined for some power values
according to the rated voltage. The table has been calculated considering cos
to be equal to 1; for different power factors, the value from Table 3 must be
multiplied by the coefficient given in Table 4 corresponding to the actual value
of the power factor (cosact).
Table 3: Load current for single-phase systems with cos = 1 or dc
systems
Ur [V]
230 400 415 440 500 600 690
P [kW] Ib [A]
0.03 0.13 0.08 0.07 0.07 0.06 0.05 0.04
0.04 0.17 0.10 0.10 0.09 0.08 0.07 0.06
0.06 0.26 0.15 0.14 0.14 0.12 0.10 0.09
0.1 0.43 0.25 0.24 0.23 0.20 0.17 0.14
0.2 0.87 0.50 0.48 0.45 0.40 0.33 0.29
0.5 2.17 1.25 1.20 1.14 1.00 0.83 0.72
1 4.35 2.50 2.41 2.27 2.00 1.67 1.45
2 8.70 5.00 4.82 4.55 4.00 3.33 2.90
5 21.74 12.50 12.05 11.36 10.00 8.33 7.25
10 43.48 25.00 24.10 22.73 20.00 16.67 14.49
20 86.96 50.00 48.19 45.45 40.00 33.33 28.99

210 ABB SACE - Electrical devices

 Calculation of load curremt Ib

Annex B: Calculation of load current Ib

Ur [V]
230 400 415 440 500 600 690
P [kW] Ib [A]
30 130.43 75.00 72.29 68.18 60.00 50.00 43.48
40 173.91 100.00 96.39 90.91 80.00 66.67 57.97
50 217.39 125.00 120.48 113.64 100.00 83.33 72.46
60 260.87 150.00 144.58 136.36 120.00 100.00 86.96
70 304.35 175.00 168.67 159.09 140.00 116.67 101.45
80 347.83 200.00 192.77 181.82 160.00 133.33 115.94
90 391.30 225.00 216.87 204.55 180.00 150.00 130.43
100 434.78 250.00 240.96 227.27 200.00 166.67 144.93
110 478.26 275.00 265.06 250.00 220.00 183.33 159.42
120 521.74 300.00 289.16 272.73 240.00 200.00 173.91
130 565.22 325.00 313.25 295.45 260.00 216.67 188.41
140 608.70 350.00 337.35 318.18 280.00 233.33 202.90
150 652.17 375.00 361.45 340.91 300.00 250.00 217.39
200 869.57 500.00 481.93 454.55 400.00 333.33 289.86
250 1086.96 625.00 602.41 568.18 500.00 416.67 362.32
300 1304.35 750.00 722.89 681.82 600.00 500.00 434.78
350 1521.74 875.00 843.37 795.45 700.00 583.33 507.25
400 1739.13 1000.00 963.86 909.09 800.00 666.67 579.71
450 1956.52 1125.00 1084.34 1022.73 900.00 750.00 652.17
500 2173.91 1250.00 1204.82 1136.36 1000.00 833.33 724.64
550 2391.30 1375.00 1325.30 1250.00 1100.00 916.67 797.10
600 2608.70 1500.00 1445.78 1363.64 1200.00 1000.00 869.57
650 2826.09 1625.00 1566.27 1477.27 1300.00 1083.33 942.03
700 3043.48 1750.00 1686.75 1590.91 1400.00 1166.67 1014.49
750 3260.87 1875.00 1807.23 1704.55 1500.00 1250.00 1086.96
800 3478.26 2000.00 1927.71 1818.18 1600.00 1333.33 1159.42
850 3695.65 2125.00 2048.19 1931.82 1700.00 1416.67 1231.88
900 3913.04 2250.00 2168.67 2045.45 1800.00 1500.00 1304.35
950 4130.43 2375.00 2289.16 2159.09 1900.00 1583.33 1376.81
1000 4347.83 2500.00 2409.64 2272.73 2000.00 1666.67 1449.28

Table 4: Correction factors for load current with cos other than 1

cosact 1 0.95 0.9 0.85 0.8 0.75 0.7

kcos* 1 1.053 1.111 1.176 1.25 1.333 1.429

1
*
For cosact values not present in the table, kcos =
cos act
Lighting circuits
The current absorbed by the lighting system may be deduced from the lighting
equipment catalogue, or approximately calculated using the following formula:
PL nL kBkN
Ib=
where: U rL cos
PL is the power of the lamp [W];
nL is the number of lamps per phase;
kB is a coefficient which has the value:
- 1 for lamps which do not need any auxiliary starter;
- 1.25 for lamps which need auxiliary starters;
kN is a coefficient which has the value:
- 1 for star-connected lamps;
- for delta-connected lamps;
UrL is the rated voltage of the lamps;
cos is the power factor of the lamps which has the value:
- 0.4 for lamps without compensation;
- 0.9 for lamps with compensation.
ABB SACE - Electrical devices 211
 Calculation of load curremt Ib

Annex B: Calculation of load current Ib

Motors
Table 5 gives the approximate values of the load current for some three-phase
squirrel-cage motors, 1500 rpm at 50 Hz, according to the rated voltage.
Note: these values are given for information only, and may vary according to the motor manifacturer
and depending on the number of poles
Table 5: Motor load current
Motor power Rated current of the motor at:

220-230 V 240 V 380-400 V 415 V 440 V 500 V 600 V 660-690 V

[kW] PS = hp [A] [A] [A] [A] [A] [A] [A] [A]
0.06 1/12 0.38 0.35 0.22 0.20 0.19 0.16 0.12
0.09 1/8 0.55 0.50 0.33 0.30 0.28 0.24 0.21
0.12 1/6 0.76 0.68 0.42 0.40 0.37 0.33 0.27
0.18 1/4 1.1 1 0.64 0.60 0.55 0.46 0.40
0.25 1/3 1.4 1.38 0.88 0.85 0.76 0.59 0.56
0.37 1/2 2.1 1.93 1.22 1.15 1.06 0.85 0.77 0.7
0.55 3/4 2.7 2.3 1.5 1.40 1.25 1.20 1.02 0.9
0.75 1 3.3 3.1 2 2 1.67 1.48 1.22 1.1
1.1 1.5 4.9 4.1 2.6 2.5 2.26 2.1 1.66 1.5
1.5 2 6.2 5.6 3.5 3.5 3.03 2.6 2.22 2
2.2 3 8.7 7.9 5 5 4.31 3.8 3.16 2.9
2.5 3.4 9.8 8.9 5.7 5.5 4.9 4.3 3.59 3.3
3 4 11.6 10.6 6.6 6.5 5.8 5.1 4.25 3.5
3.7 5 14.2 13 8.2 7.5 7.1 6.2 5.2 4.4
4 5.5 15.3 14 8.5 8.4 7.6 6.5 5.6 4.9
5 6.8 18.9 17.2 10.5 10 9.4 8.1 6.9 6
5.5 7.5 20.6 18.9 11.5 11 10.3 8.9 7.5 6.7
6.5 8.8 23.7 21.8 13.8 12.5 12 10.4 8.7 8.1
7.5 10 27.4 24.8 15.5 14 13.5 11.9 9.9 9
8 11 28.8 26.4 16.7 15.4 14.4 12.7 10.6 9.7
9 12.5 32 29.3 18.3 17 15.8 13.9 11.6 10.6
11 15 39.2 35.3 22 21 19.3 16.7 14.1 13
12.5 17 43.8 40.2 25 23 21.9 19 16.1 15
15 20 52.6 48.2 30 28 26.3 22.5 19.3 17.5
18.5 25 64.9 58.7 37 35 32 28.5 23.5 21
20 27 69.3 63.4 40 37 34.6 30.6 25.4 23
22 30 75.2 68 44 40 37.1 33 27.2 25
25 34 84.4 77.2 50 47 42.1 38 30.9 28
30 40 101 92.7 60 55 50.1 44 37.1 33
37 50 124 114 72 66 61.9 54 45.4 42
40 54 134 123 79 72 67 60 49.1 44
45 60 150 136 85 80 73.9 64.5 54.2 49
51 70 168 154 97 90 83.8 73.7 61.4 56
55 75 181 166 105 96 90.3 79 66.2 60
59 80 194 178 112 105 96.9 85.3 71.1 66
75 100 245 226 140 135 123 106 90.3 82
80 110 260 241 147 138 131 112 96.3 86
90 125 292 268 170 165 146 128 107 98
100 136 325 297 188 182 162 143 119 107
110 150 358 327 205 200 178 156 131 118
129 175 420 384 242 230 209 184 153 135
132 180 425 393 245 242 214 186 157 140
140 190 449 416 260 250 227 200 167 145
147 200 472 432 273 260 236 207 173 152
160 220 502 471 295 280 256 220 188 170
180 245 578 530 333 320 289 254 212 190
184 250 590 541 340 325 295 259 217 200
200 270 626 589 370 340 321 278 235 215
220 300 700 647 408 385 353 310 260 235
250 340 803 736 460 425 401 353 295 268
257 350 826 756 475 450 412 363 302 280
295 400 948 868 546 500 473 416 348 320
315 430 990 927 580 535 505 445 370 337
355 480 1080 1010 636 580 549 483 405 366
400 545 1250 1130 710 650 611 538 450 410
450 610 1410 1270 800 740 688 608 508 460
475 645 1490 1340 850 780 730 645 540 485
500 680 1570 1420 890 830 770 680 565 510
560 760 1750 1580 1000 920 860 760 630 570
600 810 1080 990 920 810 680 610
670 910 1200 1100 1030 910 760 680

212 ABB SACE - Electrical devices

 Calculation of short-circuit current

Annex C: Calculation of short-circuit current

A short-circuit is a fault of negligible impedance between live conductors having
a difference in potential under normal operating conditions.

Fault typologies
In a three-phase circuit the following types of fault may occur:
three phase fault;
two phase fault;
phase to neutral fault;
phase to PE fault.
In the formulas, the following symbols are used:
Ik short-circuit current;
Ur rated voltage;
ZL phase conductor impedance;
ZN neutral conductor impedance;
ZPE protective conductor impedance.
The following table briefly shows the type of fault and the relationships between
the value of the short-circuit current for a symmetrical fault (three phase) and
the short-circuit current for asymmetrical faults (two phase and single phase) in
case of faults far from generators. For more accurate calculation, the use of
DOCWin software is recommended.

Three phase fault

ZL IkLLL

ZL IkLLL
ZC = R C2 + X C2
ZL IkLLL

ZN

Two phase fault

ZL

ZL
Ur 3
IkLL = = IkLLL = 0.87 IkLLL
ZL IkLL 2Z L 2

ZN

ABB SACE - Electrical devices 213

 Calculation of short-circuit current

Annex C: Calculation of short-circuit current

Phase to neutral fault Ur

IkLN =
ZL 3( ZL + ZN )
If Z L = Z N (cross section of neutral conductor equal to the
phase conductor one):

ZL Ur Ur
IkLN = = = 0.5 IkLLL
3( ZL + ZN ) 3(2ZL )
If Z N = 2Z L (cross section of neutral conductor half the phase
ZL conductor one):
Ur Ur
IkLN = = = 0.33IkLLL
3( ZL + ZN ) 3(3Z L )
ZN IkLN If Z N 0 limit condition:
Ur Ur
IkLN = = = I kLLL
3( ZL + ZN ) 3( ZL )

Phase to PE fault IkLPE = Ur

ZL 3( ZL + ZPE )
If Z L = Z PE (cross section of protective conductor equal
to the phase conductor one):
Ur Ur
ZL IkLPE = = = 0.5I kLLL
3( ZL + ZPE ) 3(2ZL )
If Z PE= 2Z L (cross section of protective conductor
ZL half to the phase conductor one):
Ur Ur
IkLPE = = = 0.33I kLLL
3(ZL + ZPE ) 3(3ZL )
ZPE IkLPE If Z PE 0 limit condition:
IkLPE = Ur Ur
= = IkLLL
3( ZL + ZPE ) 3 (ZL)

The following table allows the approximate value of a short-circuit current to be

found quickly.

Three-phase Two-phase Phase to neutral Phase to PE short-circuit

Note short-circuit short-circuit short-circuit (TN system)

IkLLL IkLL IkLN IkLPE

ILN=0.5IkLLL (ZL = ZN) ILPE=0.5IkLLL (ZL = ZPE)
IkLLL - IkLL=0.87IkLLL ILN=0.33IkLLL (ZL = 0,5ZN) ILPE=0.33IkLLL (ZL = 0.5ZPE)
ILN=IkLLL (ZN 0) ILPE=IkLLL (ZPE 0)
IkLN=0.58IkLL (ZL = ZN) IkLPE=0.58IkLL (ZL = ZPE)
IkLL IkLLL=1.16IkLL - IkLN=0.38IkLL (ZL = 0,5ZN) IkLPE=0.38IkLL (ZL = 0.5ZPE)
IkLN=1.16IkLL (ZN 0) IkLPE=1.16IkLL (ZPE 0)
IkLLL=2IkLN (ZL = ZN) IkLL=1.73IkLN (ZL = ZN)
IkLN IkLLL=3IkLN (ZL = 2ZN) IkLL=2.6IkLN (ZL = 2ZN) -
IkLLL=IkLN (ZN 0) IkLL=0.87IkLN (ZN 0)

214 ABB SACE - Electrical devices

 Calculation of short-circuit current

Annex C: Calculation of short-circuit current

Determination of the short-circuit current

In order to determine the short-circuit current the short-circuit power method
can be used. This method allows the determination of the approximate short-
circuit current at a point in an installation in a simple way; the resultant value is
generally acceptable. However, this method is not conservative and gives more
accurate values, the more similar the power factors of the considered
components are (network, generators, transformers, motors and large section
cables etc.).
For more accurate calculation, the use of DOCWin software for the dimensioning
of installations is recommended.
The short-circuit power method calculates the short-circuit current Ik based
on the formula:
Sk
Three-phase short-circuit Ik =
3 Ur

Sk
Two-phase short-circuit Ik =
2 Ur
where:
Sk is the short-circuit apparent power seen at the point of the fault;
Ur is the rated voltage.

To determine the short-circuit apparent power Sk, all the elements of the network
shall be taken into account, which may be:
elements which contribute to the short-circuit current:
network, generators, motors;
elements which limit the value of the short-circuit current:
conductors and transformers.

The procedure for the calculation of the short-circuit current involves the following
steps:
1. calculation of the short-circuit power for the different elements of the
installation;
2. calculation of the short-circuit power at the fault point;
3. calculation of the short-circuit current.

Calculation of the short-circuit power for the different elements of

the installation
The short-circuit apparent power Sk shall be determined for all the
components which are part of the installation:

Network
An electrical network is considered to include everything upstream of the point
of energy supply.

ABB SACE - Electrical devices 215

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Annex C: Calculation of short-circuit current

Generally, the energy distribution authority supplies the short-circuit apparent

power (Sknet) value at the point of energy supply. However, if the value of the
short-circuit current Iknet is known, the value of the power can be obtained by
using, for three-phase systems, the following formula:

S knet = 3Ur Iknet

where Ur is the rated voltage at the point of energy supply.

If the aforementioned data are not available, the values for Sknet given in the
following table can be taken as reference values:

Net voltage Ur [kV] Short-circuit power Sknet [MVA]

Up to 20 500
Up to 32 750
Up to 63 1000

Generator
The short-circuit power is obtained from:

Sr 100
Skgen =
X* d%

where X*d% is the percentage value of the subtransient reactance (Xd) or of the
transient reactance (Xd) or of the synchronous reactance (Xd), according to the
instant in which the value of the short-circuit power is to be evaluated.
In general, the reactances are expressed in percentages of the rated impedance
of the generator (Zd) given by:
2
Ur
Zd =
Sr
where Ur and Sr are the rated voltage and power of the generator.
Typical values can be:
- Xd from 10 % to 20 %;
- Xd from 15 % to 40 %;
- Xd from 80 % to 300 %.
Normally, the worst case is considered, that being the subtransient reactance.
The following table gives the approximate values of the short-circuit power of
generators (Xd = 12.5 %):

Sr [kVA] 50 63 125 160 200 250 320 400 500 630 800 1000 1250 1600 2000 2500 3200 4000
Skgen [MVA] 0.4 0.5 1.0 1.3 1.6 2.0 2.6 3.2 4.0 5.0 6.4 8.0 10.0 12.8 16.0 20.0 25.6 32.0

216 ABB SACE - Electrical devices

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Annex C: Calculation of short-circuit current

Asynchronous three phase motors

Under short circuit conditions, electric motors contribute to the fault for a brief
period (5-6 periods).
The power can be calculated according to the short circuit current of the motor
(Ik), by using the following expression:

Skmot = 3 U r I k

Typical values are:

Skmot= 57 Srmot
(Ik is about 57 Irmot: 5 for motors of small size, and 7 for larger motors).

Transformers
The short circuit power of a transformer (Sktrafo) can be calculated by using the
following formula:
100
Sktrafo = Sr
uk %
The following table gives the approximate values of the short circuit power of
transformers:

Sr [kVA] 50 63 125 160 200 250 320 400 500 630 800 1000 1250 1600 2000 2500 3200 4000
uk% 4 4 4 4 4 4 4 4 4 4 5 5 5 6 6 6 6 6
Sktrafo [MVA] 1.3 1.6 3.1 4 5 6.3 8 10 12.5 15.8 16 20 25 26.7 33.3

Cables
A good approximation of the short-circuit power of cables is:
2
Ur
S kcable =
Zc
where the impedance of the cable (Zc) is:
2 2
ZC = RC + X C

The following table gives the approximate values of the short-circuit power of
cables, at 50 and 60 Hz, according to the supply voltage (cable length = 10 m):

ABB SACE - Electrical devices 217

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Annex C: Calculation of short-circuit current

230 [V] 400 [V] 440 [V] 500 [V] 690 [V] 230 [V] 400 [V] 440 [V] 500 [V] 690 [V]
S [mm2] Skcable [MVA] @50 Hz Skcable [MVA] @60 Hz
1.5 0.44 1.32 1.60 2.07 3.94 0.44 1.32 1.60 2.07 3.94
2.5 0.73 2.20 2.66 3.44 6.55 0.73 2.20 2.66 3.44 6.55
4 1.16 3.52 4.26 5.50 10.47 1.16 3.52 4.26 5.50 10.47
6 1.75 5.29 6.40 8.26 15.74 1.75 5.29 6.40 8.26 15.73
10 2.9 8.8 10.6 13.8 26.2 2.9 8.8 10.6 13.7 26.2
16 4.6 14.0 16.9 21.8 41.5 4.6 13.9 16.9 21.8 41.5
25 7.2 21.9 26.5 34.2 65.2 7.2 21.9 26.4 34.1 65.0
35 10.0 30.2 36.6 47.3 90.0 10.0 30.1 36.4 47.0 89.6
50 13.4 40.6 49.1 63.4 120.8 13.3 40.2 48.7 62.9 119.8
70 19.1 57.6 69.8 90.1 171.5 18.8 56.7 68.7 88.7 168.8
95 25.5 77.2 93.4 120.6 229.7 24.8 75.0 90.7 117.2 223.1
120 31.2 94.2 114.0 147.3 280.4 29.9 90.5 109.5 141.5 269.4
150 36.2 109.6 132.6 171.2 326.0 34.3 103.8 125.6 162.2 308.8
185 42.5 128.5 155.5 200.8 382.3 39.5 119.5 144.6 186.7 355.6
240 49.1 148.4 179.5 231.8 441.5 44.5 134.7 163.0 210.4 400.7
300 54.2 164.0 198.4 256.2 488.0 48.3 146.1 176.8 228.3 434.7

With n cables in parallel, it is necessary to multiply the value given in the table
by n. If the length of the cable (Lact) is other than 10 m, it is necessary to
multiply the value given in the table by the following coefficient:
10
L act
Calculation of the short-circuit power at the fault point
The rule for the determination of the short-circuit power at a point in the
installation, according to the short-circuit power of the various elements of the
circuit, is analogue to that relevant to the calculation of the equivalent admittance.
In particular:
the power of elements in series is equal to the inverse of the sum of the
inverses of the single powers (as for the parallel of impedances);
1
Sk =
1
S
i
the short-circuit power of elements in parallel is equal to the sum of the single
short-circuit powers (as for the series of impedances).

Sk = S i

The elements of the circuit are considered to be in series or parallel, seeing the
circuit from the fault point.
In the case of different branches in parallel, the distribution of the current between
the different branches shall be calculated once the short-circuit current at the
fault point has been calculated. This must be done to ensure the correct choice
of protection devices installed in the branches.

218 ABB SACE - Electrical devices

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Annex C: Calculation of short-circuit current

Calculation of the short-circuit current

To determine the short-circuit current in an installation, both the fault point as
well as the configuration of the system which maximize the short-circuit current
involving the device shall be considered. If appropriate, the contribution of the
motors shall be taken into account.
For example, in the case detailed below, for circuit-breaker CB1, the worst
condition occurs when the fault is right upstream of the circuit-breaker itself. To
determine the breaking capacity of the circuit-breaker, the contribution of two
transformers in parallel must be considered.

Fault right downstream of CB1

1SDC010050F0001
CB1 CB2 CB3
Fault

Fault right upstream of CB1

(worst condition for CB1)

Fault
1SDC010051F0001

CB1 CB2 CB3

Once the short-circuit power equivalent at the fault point has been determined,
the short-circuit current can be calculated by using the following formula:

Sk
Three-phase short-circuit Ik =
3 Ur

Sk
Two-phase short-circuit Ik =
2 Ur

ABB SACE - Electrical devices 219

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Annex C: Calculation of short-circuit current

As a first approximation, by using the following graph, it is possible to evaluate

the three phase short-circuit current downstream of an object with short-circuit
power (SkEL) known; corresponding to this value, knowing the short-circuit
power upstream of the object (SkUP), the value of Ik can be read on the y-axis,
expressed in kA, at 400 V.

Figure 1: Chart for the calculation of the three phase short-circuit

current at 400 V

Ik [kA]
150

140
SkUP = 1000 MVA
130
SkUP
SkUP = 750 MVA
120 SkUP =
SkUP = 500 MVA
110
SkEL
100
SkUP = 250 MVA
90
Ik
80

70
SkUP = 100 MVA
60
SkUP = 50 MVA
50

40
SkUP = 40 MVA
30 SkUP = 30 MVA

20 SkUP = 20 MVA
1SDC010052F0001

10 SkUP = 10 MVA

0
0 10 20 30 40 50 60 70 80 90 100 SkEL [MVA]

220 ABB SACE - Electrical devices

 Calculation of short-circuit current

Annex C: Calculation of short-circuit current

Examples:
The following examples demonstrate the calculation of the short-circuit current
in some different types of installation.

Example 1 U
Upstream network: Ur = 20000 V A
Sknet = 500 MVA

Transformer: Sr = 1600 kVA

uk% = 6%
CB1
U1r / U2r =20000/400
B
Motor: Pr = 220 kW
CB2 CB3

1SDC010053F0001
Ikmot/Ir = 6.6
cosr = 0.9
= 0.917

Generic load: IrL= 1443.4 A

M L
cosr= 0.9

Calculation of the short-circuit power of different elements

Network: Sknet= 500 MVA

100
Transformer: S ktrafo = S r = 26.7 MVA
uk %

Pr
Motor: S rmot = = 267 kVA
cos r

Skmot = 6.6.Srmot = 1.76 MVA for the first 5-6 periods (at 50 Hz about 100 ms)

Calculation of the short-circuit current for the selection of circuit-breakers

Selection of CB1
For circuit-breaker CB1, the worst condition arises when the fault occurs right
downstream of the circuit-breaker itself. In the case of a fault right upstream,
the circuit-breaker would be involved only by the fault current flowing from the
motor, which is remarkably smaller than the network contribution.

ABB SACE - Electrical devices 221

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Annex C: Calculation of short-circuit current

The circuit, seen from the fault point, is represented by the series of the network
with the transformer. According to the previous rules, the short-circuit power is
determined by using the following formula:
S knet S ktrafo
S kCB1 = = 25.35 MVA
S knet + S ktrafo
the maximum fault current is:
S kCB1
IkCB1 = = 36.6 kA
3 Ur
The transformer LV side rated current is equal to 2309 A; therefore the circuit-
breaker to select is an Emax E3N 2500.
Using the chart shown in Figure 1, it is possible to find IkCB1 from the curve with
SkUP = Sknet = 500 MVA corresponding to SkEL = Sktrafo = 26.7 MVA:

Ik [kA]
150

140

130

120

110 SkUP = 500 MVA

100

90

80

70

60

50

40
Ik = 36.5 kA
30
1SDC010054F0001

20

10

0
0 10 20 30 40 50 60 70 80 90 100
SkUP = 26.7 MVA SkEL [MVA]

222 ABB SACE - Electrical devices

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Annex C: Calculation of short-circuit current

Selection of CB2
For circuit-breaker CB2, the worst condition arises when the fault occurs right
downstream of the circuit-breaker itself. The circuit, seen from the fault point, is
represented by the series of the network with the transformer. The short-circuit
current is the same used for CB1.
SkCB1
IkCB1 = = 36.6 kA
3 Ur
The rated current of the motor is equal to 385 A; the circuit-breaker to select is
an Isomax S5H 400.

Selection of CB3
For CB3 too, the worst condition arises when the fault occurs right downstream
of the circuit-breaker itself.
The circuit, seen from the fault point, is represented by two branches in parallel:
the motor and the series of the network and transformer. According to the
previous rules, the short circuit power is determined by using the following
formula:
Motor // (Network + Transformer)
1
S kCB3 = Skmot + = 27.11 MVA
1 1
+
S knet Sktrafo

SkCB3
IkCB3 = = 39.13 kA
3 Ur
The rated current of the load L is equal to 1443 A; the circuit-breaker to select
is a SACE Isomax S7S 1600, or an Emax E2N1600.

Example 2
The circuit shown in the diagram is constituted by the supply, two transformers
in parallel and three loads.
U

Trafo 1 Trafo 2
Upstream network: Ur1=20000 V
Sknet = 500 MVA
CB1 CB2
Transformers 1 and 2: Sr = 1600 kVA
uk% = 6% B
U1r /U2r =20000/400
1SDC010055F0001

CB3 CB4 CB5

Load L1: Sr = 1500 kVA; cos = 0.9;

Load L2: Sr = 1000 kVA; cos = 0.9;
Load L3: Sr = 50 kVA; cos = 0.9.
L1 L2 L3

ABB SACE - Electrical devices 223

 Calculation of short-circuit current

Annex C: Calculation of short-circuit current

Calculation of the short-circuit powers of different elements:

Network Sknet = 500 MVA

Sr
Transformers 1 and 2 S ktrafo = . 100 = 26.7 MVA
uk %

Selection of CB1 (CB2)

For circuit-breaker CB1 (CB2) the worst condition arises when the fault occurs
right downstream of the circuit-breaker itself. According to the previous rules,
the circuit seen from the fault point, is equivalent to the parallel of the two
transformers in series with the network: Network + (Trafo 1 // Trafo 2).
The short-circuit current obtained in this way corresponds to the short-circuit
current at the busbar. This current, given the symmetry of the circuit, is distributed
equally between the two branches (half each). The current which flows through
CB1 (CB2) is therefore equal to half of that at the busbar.

S knet (Srtrafo1 + S ktrafo2 )

S kbusbar = = 48.2 MVA
S knet + (Sktrafo1 + S ktrafo2 )

S kbusbar
Ikbusbar = = 69.56 kA
3 Ur

Ikbusbar
IkCB1(2) = = 34.78 kA
2

The circuit-breakers CB1(CB2) to select, with reference to the rated current of

the transformers, are Emax E3N 2500.

Selection of CB3-CB4-CB5
For these circuit-breakers the worst condition arises when the fault occurs
right downstream of the circuit-breakers themselves. Therefore, the short-circuit
current to be taken into account is that at the busbar:

IkCB3 = Ikbusbar = 69.56 kA

The circuit-breakers to select, with reference to the current of the loads, are:
CB3: Emax E3S 2500
CB4: Emax E3S 1600
CB5: Tmax T2H 160

224 ABB SACE - Electrical devices

 Calculation of short-circuit current

Annex C: Calculation of short-circuit current

Determination of the short-circuit current Ik downstream

of a cable as a function of the upstream one
The table below allows the determination, in a conservative way, of the three-
phase short-circuit current at a point in a 400 V network downstream of a
single pole copper cable at a temperature of 20 C. Known values:
- the three phase short-circuit current upstream of the cable;
- the length and cross section of the cable.
Cable
section Length
[mm2] [m]
1.5 0.9 1.1 1.4 1.8 2.5 3.5 5.3 7 9.4 14
2.5 0.9 1 1.2 1.5 1.8 2.3 2.9 4.1 5.9 8.8 12 16 24
4 0.9 1.2 1.4 1.6 1.9 2.3 2.8 3.7 4.7 6.6 9.4 14 19 25 38
6 0.8 1.1 1.4 1.8 2.1 2.5 2.8 3.5 4.2 5.6 7 10 14 21 28 38 56
10 0.9 1.2 1.4 1.9 2.3 2.9 3.5 4.1 4.7 5.8 7 9.4 12 16 23 35 47 63 94
16 0.9 1.1 1.5 1.9 2.2 3 3.7 4.7 5.6 6.5 7.5 9.3 11 15 19 26 37 56 75 100 150
25 0.9 1.2 1.4 1.7 2.3 2.9 3.5 4.6 5.8 7.2 8.7 10 12 14 17 23 29 41 58 87 116 155 233
35 1.2 1.6 2 2.4 3.2 4 4.8 6.4 8 10 12 14 16 20 24 32 40 56 80 121 161 216 324
50 1.1 1.7 2.3 2.8 3.4 4.5 5.7 6.8 9 11 14 17 20 23 28 34 45 57 79 113 170 226 303 455
70 0.8 1.5 2.3 3.1 3.8 4.6 6.2 7.7 9.2 12 15 19 23 27 31 38 46 62 77 108 154 231 308 413
95 1 2 3 4 5 6 8 10 12 16 20 25 30 35 40 50 60 80 100 140 200 300 400
120 1.2 2.4 3.6 4.8 6 7.2 10 12 14 19 24 30 36 42 48 60 72 96 120 168 240 360 481
150 1.4 2.8 4.2 5.6 7 8.4 11 14 17 23 28 35 42 49 56 70 84 113 141 197 281 422
185 1.6 3.2 4.8 6.4 8 10 13 16 19 26 32 40 48 56 64 80 96 128 160 224 320 480
240 1.8 3.7 5.5 7.3 9.1 11 15 18 22 29 37 46 55 64 73 91 110 146 183 256 366 549
300 2 4 6 8 10 12 16 20 24 32 40 50 60 70 80 100 120 160 200 280 400
2x120 2.4 4.8 7.2 10 12 14 19 24 29 38 48 60 72 84 96 120 144 192 240 336 481
2x150 2.8 5.6 8.4 11 14 17 23 28 34 45 56 70 84 98 113 141 169 225 281 394 563
2x185 3.2 6.4 10 13 16 19 26 32 38 51 64 80 96 112 128 160 192 256 320 448
3x120 3.6 7.2 11 14 18 22 29 36 43 58 72 90 108 126 144 180 216 288 360 505
3x150 4.2 8.4 13 17 21 25 34 42 51 68 84 105 127 148 169 211 253 338 422
3x185 4.8 10 14 19 24 29 38 48 58 77 96 120 144 168 192 240 288 384 480
Ik upstream Ik downstream
[kA] [kA]
100 96 92 89 85 82 78 71 65 60 50 43 36 31 27 24 20 17 13 11 7.8 5.6 3.7 2.7 2.0 1.3
90 86 83 81 78 76 72 67 61 57 48 42 35 31 27 24 20 17 13 11 7.8 5.6 3.7 2.7 2.0 1.3
80 77 75 73 71 69 66 62 57 53 46 40 34 30 27 24 20 17 13 10 7.7 5.5 3.7 2.7 2.0 1.3
70 68 66 65 63 62 60 56 53 49 43 38 33 29 26 23 19 16 13 10 7.6 5.5 3.7 2.7 2.0 1.3
60 58 57 56 55 54 53 50 47 45 40 36 31 28 25 23 19 16 12 10 7.5 5.4 3.7 2.7 2.0 1.3
50 49 48 47 46 45 44 43 41 39 35 32 29 26 23 21 18 15 12 10 7.3 5.3 3.6 2.6 2.0 1.3
40 39 39 38 38 37 37 35 34 33 31 28 26 24 22 20 17 15 12 10 7.1 5.2 3.6 2.6 2.0 1.3
35 34 34 34 33 33 32 32 31 30 28 26 24 22 20 19 16 14 11 10 7.1 5.1 3.5 2.6 2.0 1.3
30 30 29 29 29 28 28 28 27 26 25 23 22 20 19 18 16 14 11 9.3 7.0 5.0 3.5 2.6 1.9 1.3
25 25 24 24 24 24 24 23 23 22 21 21 19 18 17 16 14 13 11 9.0 6.8 5.0 3.4 2.6 1.9 1.3
20 20 20 20 19 19 19 19 18 18 18 17 16 15 15 14 13 12 10 8.4 6.5 4.8 3.3 2.5 1.9 1.3
15 15 15 15 15 15 14 14 14 14 14 13 13 12 12 12 11 10 8.7 7.6 6.1 4.6 3.2 2.5 1.9 1.3
12 12 12 12 12 12 12 12 11 11 11 11 11 10 10 10 9.3 8.8 7.8 7.0 5.7 4.4 3.1 2.4 1.9 1.3
10 10 10 10 10 10 10 10 9.5 9.4 9.2 9.0 8.8 8.5 8.3 8.1 7.7 7.3 6.5 5.9 5.0 3.9 2.9 2.3 1.8 1.2
8.0 8.0 7.9 7.9 7.9 7.8 7.8 7.7 7.7 7.6 7.5 7.4 7.2 7.1 6.9 6.8 6.5 6.2 5.7 5.2 4.5 3.7 2.8 2.2 1.7 1.2
6.0 6.0 5.9 5.9 5.9 5.9 5.8 5.8 5.8 5.7 5.6 5.5 5.4 5.3 5.2 5.1 4.9 4.8 4.4 4.1 3.6 3.1 2.4 2.0 1.6 1.1
3.0 3.0 3.0 3.0 3.0 3.0 3.0 2.9 2.9 2.9 2.9 2.9 2.8 2.8 2.8 2.7 2.7 2.6 2.5 2.4 2.2 2.0 1.7 1.4 1.2 0.9

ABB SACE - Electrical devices 225

 Calculation of short-circuit current

Annex C: Calculation of short-circuit current

Note:
In the case of the Ik upstream and the length of the cable not being included
in the table, it is necessary to consider:
- the value right above Ik upstream;
- the value right below for the cable length.
These approximations allow calculations which favour safety.
In the case of cables in parallel not present in the table, the length must be
divided by the number of cables in parallel.

Example
Data
Rated voltage = 400 V
Cable section = 120 mm2
Conductor = copper
Length = 29 m

Upstream short-
circuit current = 32 kA
400 V

Ik upstream = 32 kA

QF A

120 mm2
Cu/PVC
1SDC010056F0001

L = 29 m Ik downstream = ?

QF B QF C

Procedure
In the row corresponding to the cable cross section 120 mm2, it is possible to
find the column for a length equal to 29 m or right below (in this case 24). In the
column of upstream short-circuit current it is possible to identify the row with a
value of 32 kA or right above (in this case 35). From the intersection of this last
row with the previously identified column, the value of the downstream short-
circuit current can be read as being equal to 26 kA.

226 ABB SACE - Electrical devices

 Calculation for the cables

Annex D: Calculation of the coefficient k for

the cables (k2S2)
By using the formula (1), it is possible to determine the conductor minimum
section S, in the hypothesis that the generic conductor is submitted to an
adiabatic heating from a known initial temperature up to a specific final tempe-
rature (applicable if the fault is removed in less than 5 s):

S=
I t 2
(1)
k
where:
S is the cross section [mm2];
I is the value (r.m.s) of prospective fault current for a fault of negligible
impedance, which can flow through the protective device [A];
t is the operating time of the protective device for automatic disconnection [s];
k can be evaluated using the tables 27 or calculated according to the formula (2):

f - i
k=

Qc (B+20)
20 (
ln 1+
B+i ) (2)

where:
Qc is the volumetric heat capacity of conductor material [J/Cmm3] at 20 C;
B is the reciprocal of temperature coefficient of resistivity at 0 C for the
conductor [C];
20 is the electrical resistivity of conductor material at 20 C [mm];
i initial temperature of conductor [C];
f final temperature of conductor [C].

Table 1 shows the values of the parameters described above.

Table 1: Value of parameters for different materials

Qc (B+20)
Material

Copper
B
[C]
234.5
Qc
[J/Cmm3]
3.4510-3
20
[mm]
17.24110-6
20
226
Aluminium 228 2.510-3 28.26410-6 148
Lead 230 1.4510-3 21410-6 41
Steel 202 3.810-3 13810-6 78

ABB SACE - Electrical devices 227

 Calculation for the cables

Annex D: Calculation of the coefficient k for

the cables (k2S2)
Table 2: Values of k for phase conductor
Conductor insulation
PVC PVC EPR Rubber Mineral
300 mm2 300 mm2 XLPE 60 C PVC Bare
Initial temperature C 70 70 90 60 70 105
Final temperature C 160 140 250 200 160 250
Material of conductor:
copper 115 103 143 141 115 135/115 a
aluminium 76 68 94 93 - -
tin-soldered joints 115 - - - - -
in copper conductors
a
This value shall be used for bare cables exposed to touch.

Table 3: Values of k for insulated protective conductors not

incorporated in cables and not bunched with other cables
Temperature C b Material of conductor
Copper Aluminium Steel
Conductor insulation Initial Final Value for k
70 C PVC 30 160/140 a 143/133 a 95/88 a 52/49 a
90 C PVC 30 160/140 a 143/133 a 95/88 a 52/49 a
90 C thermosetting 30 250 176 116 64
60 C rubber 30 200 159 105 58
85 C rubber 30 220 166 110 60
Silicone rubber 30 350 201 133 73
a
The lower value applies to PVC insulated conductors of cross section greater than
300 mm2 .
b
Temperature limits for various types of insulation are given in IEC 60724.

Table 4: Values of k for bare protective conductors in contact with

cable covering but not bunched with other cables
Temperature C a Material of conductor
Copper Aluminium Steel
Cable covering Initial Final Value for k
PVC 30 200 159 105 58
Polyethylene 30 150 138 91 50
CSP 30 220 166 110 60
a
Temperature limits for various types of insulation are given in IEC 60724.

228 ABB SACE - Electrical devices

 Calculation for the cables

Annex D: Calculation of the coefficient k for

the cables (k2S2)
Table 5: Values of k for protective conductors as a core incorporated in
a cable or bunched with other cables or insulated conductors
Temperature C b Material of conductor
Copper Aluminium Steel
Conductor insulation Initial Final Value for k
70 C PVC 70 160/140 a 115/103 a 76/68 a 42/37 a
90 C PVC 90 160/140 a 100/86 a 66/57 a 36/31 a
90 C thermosetting 90 250 143 94 52
60 C rubber 60 200 141 93 51
85 C rubber 85 220 134 89 48
Silicone rubber 180 350 132 87 47
a
The lower value applies to PVC insulated conductors of cross section greater than
300 mm2 .
b
Temperature limits for various types of insulation are given in IEC 60724..

Table 6: Values of k for protective conductors as a metallic layer of a

cable e.g. armour, metallic sheath, concentric conductor, etc.
Temperature C Material of conductor
Copper Aluminium Lead Steel
Conductor insulation Initial Final Value for k
70 C PVC 60 200 141 93 26 51
90 C PVC 80 200 128 85 23 46
90 C thermosetting 80 200 128 85 23 46
60 C rubber 55 200 144 95 26 52
85 C rubber 75 220 140 93 26 51
Mineral PVC covered a 70 200 135 - - -
Mineral bare sheath 105 250 135 - - -
a
This value shall also be used for bare conductors exposed to touch or in contact with
combustible material.

Table 7: Value of k for bare conductors where there is no risk of damage

to any neighbouring material by the temperature indicated
Material of conductor
Copper Aluminium Steel
Initial Maximum Maximum Maximum
temperature temperature temperature temperature
Conductor insulation C k value C k value C k value C
Visible and in restricted area 30 228 500 125 300 82 500
Normal conditions 30 159 200 105 200 58 200
Fire risk 30 138 150 91 150 50 150

ABB SACE - Electrical devices 229

 Main physical quantities

Annex E: Main physical quantities and

electrotechnical formulas
The International System of Units (SI)
SI Base Units
Quantity Symbol Unit name
Length m metre
Mass kg kilogram
Time s Second
Electric Current A ampere
Thermodynamic Temperature K kelvin
Amount of Substance mol mole
Luminous Intensity cd candela

Metric Prefixes for Multiples and Sub-multiples of Units

Decimal power Prefix Symbol Decimal power Prefix Symbol

1024 yotta Y 10-1 deci d
1021 zetta Z 10-2 centi c
1018 exa E 10-3 milli m
1015 peta P 10-6 mikro
1012 tera T 10-9 nano n
109 giga G 10-12 pico p
106 mega M 10-15 femto f
103 kilo k 10-18 atto a
102 etto h 10-21 zepto z
10 deca da 10-24 yocto y

230 ABB SACE - Electrical devices

 Main physical quantities

Annex E: Main physical quantities and

electrotechnical formulas
Main quantities and SI units
Quantity SI unit Other units Conversion
Symbol Name Symbol Name Symbol Name
Length, area, volume
in inch 1 in = 25.4 mm
ft foot i ft = 30.48 cm
l length m metre fathom fathom 1 fathom = 6 ft = 1.8288 m
mile mile 1 mile = 1609.344 m
sm sea mile 1 sm = 1852 m
yd yard 1 yd = 91.44 cm
A area m2 square metre a are 1 a = 102 m2
ha hectare 1 ha = 104 m2
l litre 1 l = 1 dm3 = 10-3 m3
V volume m3 cubic metre UK pt pint 1 UK pt = 0.5683 dm3
UK gal gallon 1 UK gal = 4.5461 dm3
US gal gallon 1 US gal = 3.7855 dm3
Angles
, , plane angle rad radian degrees
.
1= rad
180
solid angle sr steradian
Mass
m mass, weight kg kilogram lb pound 1 lb = 0.45359 kg
density kg/m3 kilogram
specific volume m3/kg cubic metre
for kilogram
M moment of inertia kgm2 kilogram for
square metre
Time
t duration s second
f frequency Hz Hertz 1 Hz = 1/s
angular 1/s reciprocal second = 2pf
frequency
v speed m/s metre per second km/h kilometre 1 km/h = 0.2777 m/s
per hour
mile/h mile per hour 1 mile/h = 0.4470 m/s
knot kn 1 kn = 0.5144 m/s
g acceleration m/s2 metre per second
squared
Force, energy, power
F force N newton 1 N = 1 kgm/s2
kgf 1 kgf = 9.80665 N
p pressure/stress Pa pascal 1 Pa = 1 N/m2
bar bar 1 bar = 105 Pa
W energy, work J joule 1 J = 1 Ws = 1 Nm
P power W watt Hp horsepower 1 Hp = 745.7 W
Temperature and heat
T temperature K kelvin C Celsius T[K] = 273.15 + T [C]
F Fahrenheit T[K] = 273.15 + (5/9)(T [F]-32)
Q quantity of heat J joule
S entropy J/K joule per kelvin
Photometric quantities
I luminous intensity cd candela
L luminance cd/m2 candela per square metre
F luminous flux lm lumen 1 lm = 1 cdsr
E illuminance lux 1 lux = 1 lm/m2

ABB SACE - Electrical devices 231

 Main physical quantities

Annex E: Main physical quantities and

electrotechnical formulas
Main electrical and magnetic quantities and SI units
Quantity SI unit Other units Conversion
Symbol Name Symbol Name Symbol Name
I current A ampere
V voltage V volt
R resistance ohm
G conductance S siemens G = 1/R
X reactance ohm XL = L
XC =-1/C
B susceptance S siemens BL = -1/L
BC = C
Z impedance ohm
Y admittance S siemens
P active power W watt
Q reactive power var reactive volt
ampere
S apparent power VA volt ampere
Q electric charge C coulomb Ah ampere/hour 1 C = 1 As
1 Ah = 3600 As
E electric field V/m volt per metre
strength
C electric capacitance F farad 1 F = 1 C/V
H magnetic field A/m ampere per metre
B magnetic induction T tesla G gauss 1 T = 1 Vs/m2
1 G = 10-4 T
L inductance H henry 1 H = 1 s

Resistivity values, conductivity and temperature coefficient at

20 C of the main electrical materials
conductor conductivity temperature
resistivity 20 20=1/20 coefficient 20
[mm2/m] [m/mm2] [K-1]
Aluminium 0.0287 34.84 3.810-3
Brass, CuZn 40 0.067 15 210-3
Constantan 0.50 2 -310-4
Copper 0.0175 57.14 3.9510-3
Gold 0.023 43.5 3.810-3
Iron wire 0.1 to 0,15 10 to 6.7 4.510-3
Lead 0.208 4.81 3.910-3
Magnesium 0.043 23.26 4.110-3
Manganin 0.43 2.33 410-6
Mercury 0.941 1.06 9.210-4
Ni Cr 8020 1 1 2.510-4
Nickeline 0.43 2.33 2.310-4
Silver 0.016 62.5 3.810-3
Zinc 0.06 16.7 4.210-3

232 ABB SACE - Electrical devices

 Electrotechnical formulas

Annex E: Main physical quantities and

electrotechnical formulas
Main electrotechnical formulas
Impedance

resistance of a conductor at temperature l

R=
S

conductance of a conductor at temperature G= 1 = S

R l

resistivity of a conductor at temperature = 20 [1 + 20 ( 20)]

capacitive reactance XC= -1 = - 1

C 2 f C

inductive reactance XL= L = 2 f L

impedance Z = R + jX

module impedance Z = R2 + X2

phase impedance = arctan R

X

conductance G= 1
R

capacitive susceptance BC= -1 = C = 2 f C

XC

inductive susceptance BL= -1 = 1 = 1

XL L 2 f L

admittance Y = G jB

module admittance Y = G2 + B2

phase admittance = arctan B

G

+
Z jXL
R
R X +
U -jXC

+
Y
jBC
G
U G B +
-jBL

ABB SACE - Electrical devices 233

 Electrotechnical formulas

Annex E: Main physical quantities and

electrotechnical formulas
Indipendences in serie
Z = Z 1 + Z2 + Z3 + Z1 Z2 Z3

Admittances in serie
1
Y= Y1 Y2 Y3
1 1 1
+ + +
Y1 Y2 Y 3

Indipendences in parallel

1
Z= Z1 Z2 Z3
1 1 1
+ + +
Z1 Z2 Z3

Admittances in serie

Y = Y1 + Y 2 + Y 3 + Y1 Y2 Y3

Delta-star and star-delta transformations

1

Z1
Z13 Z12

Z3 0 Z2

3 2
Z23

Y Y
Z 1 Z2 Z12 Z13
Z12 = Z1 + Z2 + Z1 =
Z3 Z12 + Z13 + Z23

Z 2 Z3 Z12 Z23
Z23 = Z2 + Z3 + Z2 =
Z1 Z12 + Z13 + Z23
Z 3 Z1 Z23 Z13
Z13 = Z3 + Z1 + Z3 =
Z2 Z12 + Z13 + Z23

234 ABB SACE - Electrical devices

 Electrotechnical formulas

Annex E: Main physical quantities and

electrotechnical formulas
Transformers
Two-winding transformer

Sr
rated current Ir =
3 Ur
Sr
short-circuit power Sk = 100
uk%
Sk Ir
short-circuit current Ik = = 100
3 Ur uk%
uk% U2r u% Sr
longitudinal impedance ZT = = k
100 Sr 100 3 I2r
pk% U2r p% Sr
longitudinal resistance RT = = k
100 Sr 100 3 I2r
longitudinal reactance XT = ZT2 RT2

Three-winding transformer
1

Z1

Z3 Z2

3 2

u12 Ur2 1
Z12 = Z1 = (Z12 + Z13 Z23)
100 Sr12 2

u13 Ur2 1
Z13 = Z2 = (Z12 + Z23 Z13)
100 Sr13 2

u23 Ur2 1
Z23 = Z3 = (Z13 + Z23 Z12)
100 Sr23 2

ABB SACE - Electrical devices 235

 Electrotechnical formulas

Annex E: Main physical quantities and

electrotechnical formulas
Voltage drop and power

single-phase three-phase continuous

voltage drop U = 2 I l (r cos x sin) U = 3 I l (r cos x sin) U = 2 I l r

perceutage U U U
voltage drop u = 100 u = 100 u = 100
Ur Ur Ur
active power P = U I cos P = 3 U I cos P= UI
reactive power Q = U I sin Q = 3 U I sin
apparent power S=UI= P +Q 2 2 S= 3UI= P +Q 2 2

P P
power factor cos = cos =
S S

power loss P = 2 l r I2 P = 3 l r I2 P = 2 l r I2

Caption
20 resistivity at 20 C
l total length of conductor
S cross section of conductor
20 temperature coefficient of conductor at 20 C
temperature of conductor
resistivity against the conductor temperature
angular frequency
f frequency
r resistance of conductor per length unit
x reactance of conductor per length unit
uk% short-circuit percentage voltage of the transformer
Sr rated apparent power of the transformer
Ur rated voltage of the transformer
pk% percentage impedance losses of the transformer under short-circuit
conditions

236 ABB SACE - Electrical devices

copertine 2004 21-02-2004 12:18 Pagina 2
C M Y CM MY CY CMY K

Electrical installation handbook

Volume 2 Electrical devices
nd
2 edition

1SDC010001D0202

Electrical devices
02/04
1SDC010001D0202
Printed in Italy

Due to possible developments of standards as well as of

materials, the characteristics and dimensions specified in
this document may only be considered binding after
confirmation by ABB SACE.

ABB SACE S.p.A.

An ABB Group Company
L.V. Breakers
Via Baioni, 35
24123 Bergamo - Italy ABB SACE
Tel.: +39 035.395.111 - Telefax: +39 035.395.306-433
http://www.abb.com

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