3.

INSTALLATION DESIGN

It is necessary to take into account the following procedures:

3.1) Sub - division and number of circuit

3.2) Designed circuit current
3.3) Nominal current of protective device
3.4) Application of correction factors
3.5) Size of cables
3.6) Voltage drop calculation

3.1. Sub - Division and Number of circuits: Even the smallest installation needs to be divided into
number of circuits because to:
 Divide the load -it can be conveniently and safely
Handled by the cable and switch gear.
 To take in to account likely inconvenience
In small installations it is appropriate to provide minimum of two lighting circuits, so that in the event
of protective device tripping under fault conditions, total block out is avoided.
In addition separate circuits must be provided for lighting and power, Sufficient socket outlets should
be provided to avoid extension usage as it will load the circuit

 The selection of size of cable to carry a load current involves the consideration of the
following factors:

- Design Current
-Rating and type of protective device
-Correction factors
-Grouping factor
-Thermal insulation
-Type of protection device

3.2. Design current (Ib): It is the rating of the apparatuses to be operated. It may be given by
manufacturers or if not it should be calculated as follows:

- For single phase Ib = p p-power consumed by the apparatuses

V V- single phase supply (220 v

- For three phase Ib = p

√3 xVl Vl – voltage between two lines
( 380 v)

But ac circuits may be capacitive or inductive can produce poor power factor. In addition to this,
allowance must be made for efficiency (eff) and this will have to be allowed for. In addition to this
allowance must be made for eff if equipment has moving parts. So that:

Ib = p x100 ---------- for single phase

Vxpfxeff

Ib = p x 100 --------- for three phase

√3 x vl x pf x eff

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3.3. Rating of protective Device (In)

After having established the design current of the circuit, the next stage is to determine current rating
or setting protective device. Allowance should be made for possible additional future load, the rating of
the protective device. It should not be less than design current of the circuit (In>=Ib)

The reason for this is self-evident since the protective device must be capable of passing sufficient
current for the circuit function at full load without the device operating

3.4. Correction Factors

There may be a situation in which cables can find themselves being overheated. The more obvious
are the conditions set up when over currents are carried due to:

- Overloading
- Short circuit occurred

Other include the increase in temperature when number of cables are bunched together, for instance
in conduit and trunking, which is a situation in which each cable contributes its heat to that of others
and which because of the enclosed situation, produces an environment which can quickly lead to
deterioration of the cable insulation.So to choose cable size or to determine current carrying capacity
of conductor the following factors should be considered.

1. Ambiant Temperature (ca)

It is the temperature of the immediate surroundings of the equipment and cables before the
temperature of the equipment or cables contribute to the temperature rise. The cable ratings in the
IEE regulations are of the time based upon 300c, and hence it is only above this temperature that
adverse correction is needed.

It may be necessary to measure the ambient temperature for instance in roofs or suspended floors,
where heating pipes are installed, since the ambient temperature will be higher in such confined
spaces.

2. Groupng Factor (cg)

When cables are grouped together they impart heat to each other. Therefore, the more the cables
there will be more heat they will generate, thus increasing the temperature of each cable. So if cables
are grouped they have to be derated, the amount they have to be derated is dependant upon how
they are installed.

A typical situation where correction factors need to be applied would be in the calculation of cable
sizes for lighting system in a large factory. Here many cables of the same size and loading could be
expected to be fully loaded at the same time.

Where the cables are spaced twice the diameter of the larger cable apart, no derating for grouping is
required or if the spacing between adjacent conductors is only one cable diameter the derating factor
is reduced.

3. Thermal Insulation (ci)

When cables are in contact with thermal insulation, thermal insulation reduces rate of flow of heat
from the conductors, thus rising the conductor’s temperature. This means that the current carrying

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capacity of the conductor has to be reduced to compensate for the reduction in heat loss. The size of
conductor increased in size is dependant upon the manner in which it is in contact with the insulation.

4. Protection by fuse (cf)

Because of the high fusing factor of BS 3036 fuses, the rating

Of the fuse In, should be less than or equal to 0.725Iz. Hence 0.725 is the correction factor to be
Used.

3.4. Application of Correction Factors

Some or all of the conditions outlined may affect a cable along its whole length or part of it, but not all
may affect it at the same time. So consider the following:

a) If the cable ran for the whole length, grouped with others of the same size in a high ambient
temperature and was totally surrounded with thermal insulation, it would seem logical to apply all cfs,
as they all affect the whole cable run.

Certainly the factors for the BS 3036 fuse, grouping and thermal insulation should be used hence:

Iz = In
Cg x Cf x Ci

But if the ambient temperature will have any effect on the cable as the thermal insulation, if it is
efficient will prevent heat reaching the cable. Hence apply Cg, Cf, and Ci.

b) In the figure below, the cable first runs grouped with, then leave the group and runs in high
ambient temperature, and finally enclosed in thermal insulation.

Now we have three conditions, each affecting the cable in different areas. The Bs 3036 fuse affects
the whole cable run and therefore Cf must be used, but there is no need to apply all of the remaining
factors as the worse one will automatically compensate for others.

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c) In the figure below: combination of cases a and b is considered. The effect of grouping and ambient
temperature is 0.7 x 0.97 = 0.69. The factor for thermal insulation is still worse than this combination,
and therefore Ci is the only one to be used.

- Having chosen the relevant correction factors, we now apply them to the nominal rating of the
Protection In.
Iz = In
Relevant correction factors

3.5. Choice of cable size

Having established the tabulated current carrying capacity Iz of the cable to be used, it is now remains
to choose cable to suit this value

Table –1
Maximum current rating and associated volt drop per 50 meters of PVC insulated single and multicore
copper cable, armored with or without sheath.

Enclosed in conduit of trunking Unenclosed Clipped direct to a surface of

Nominal a cable tray

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 Cross- 2 cables single 3 or 4 cables three 2 cables single 3 or 4 cables three
section phase phase phase phase
(Mm2)
Current Voltage Current Voltage Current Voltage Current Voltage
rating drop rating drop rating drop rating drop
(amp) (volt) (amp) (volt) (amp) (volt) (amp) (volt)
1 12 21.4 10 14.2 14 25.7 12 18.1
1.5 16 19.0 13 12.6 19 22.9 17 16.1
2.5 21 15.0 17 10.0 25 18.2 22 12.6
4 27 12.0 23 8.3 35 14.5 29 10.1
6 35 10.4 29 7.8 42 12.5 37 8.8
10 48 8.6 40 5.7 57 10.0 51 7.2
16 65 7.3 55 4.8 78 8.7 70 6.1
25 88 6.3 74 4.2 105 7.6 95 5.7
35 110 5.6 93 3.7 132 6.8 119 4.7
50 140 5.0 119 3.3 168 6.0 151 4.2
70 175 4.5 149 3.0 210 5.4 189 3.8
95 210 4.0 185 2.7 252 4.7 226 3.3
120 250 3.7 212 2.5 300 4.5 270 3.1
150 275 3.3 236 2.2 330 3.9 300 2.8
185 305 2.9 260 2.9 366 3.5 33 2.5
240 360 2.7 306 1.8 432 3.2 338 2.2
300 415 2.5 352 1.6 497 3.0 448 2.1

RATING –FACTORS

For ambient temperature

Temperature 35oC 40oC 45oC 50oC 55oC 60oC 65oC

Rating Factor 0.97 0.94 0.91 0.88 0.77 .63 0.44

For Groups

In all cases except where groups of circuits are unenclosed and clearances between cables is
not less than 5 times the overall diameter of an individual cable or is not less than 12 cm.

No of circuits 2 3 4 5 8 10 12 14

Rating factor 0.80 0.70 0.65 0.60 0.52 0.48 0.45 0.43

Table – 2

Maximum current rating and associated volt drop per 50 meters of PVC insulated single and
multicore aluminum cables armored with or without sheath.

Enclosed in conduit of trunking Unenclosed Clipped direct to a surface of a

Nominal cable tray

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Cross- 2 cables single 3 or 4 cables three 2 cables single 3 or 4 cables three
section phase phase phase phase
(mm2)
Current voltage Current voltage Current Voltage Current Voltage
rating drop rating drop (volt) rating drop rating drop (volt)
(amp) (volt) (amp) (amp) (volt) (amp)
2.5 16 18.8 13 12.5 19 22.6 17 15.9
4 21 15.5 17 10.3 25 18.5 22 13.0
6 27 13.3 22 8.8 32 15.9 29 11.2
10 33 11.2 32 7.4 45 13.4 41 9.4
16 51 9.4 43 6.2 61 11.5 55 7.8
25 69 8.1 58 5.4 82 9.8 74 6.8
35 86 7.2 73 4.8 103 8.7 92 6.1
50 110 6.5 93 4.3 132 7.8 119 5.5
70 135 5.7 114 3.7 162 6.8 146 4.8
95 160 5.0 136 3.3 192 6.0 173 4.2
120 185 4.5 157 3.0 222 4.5 200 3.8
150 215 4.2 183 2.8 258 5.1 232 3.5

RATING FACTORS

For ambient temperature

Temperature 35oC 40oC 45oC 50oC 55oC 60oC 65oC

Rating Factor 0.97 0.94 0.91 0.88 0.77 0.63 0.44

Table – 3

Maximum current rating and associated volt drop per 50 meters of bare or lightly insulated copper
conductor.

Nominal Voltage Drop

Cross Section Current Rating 2 Conductors 3 or 4 Conductors
(mm2) (Amp) 1- phase (volt) Three phase (volt)
2.5 25 17.8 13.9
4 35 15.0 12.2
6 54 16.0 12.5
10 75 13.4 10.4
16 100 11.1 8.7
25 130 9.3 7.2
35 150 7.6 6.0
50 200 7.1 5.6
70 240 6.1 4.8
95 315 5.9 4.6
120 360 5.3 4.2
150 420 6.0 3.9
185 460 4.6 3.6

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 240 560 4.2 3.2
300 660 3.9 3.1

Note Current rating for rectangular copper conductors shall not except 2.5 amperes per mm2

For Groups

In all cases except where groups of circuits are unenclosed and clearances between cables is
not less than 5 times the overall diameter of an individual cable or is not less than 12 cm.

No of circuits 2 3 4 5 8 10 12 14

Rating factor 0. 80 0.70 0.65 0.60 0.52 0.48 0.45 0.43

Table 4

Maximum current rating and associated volt drop per 50 meters of bare or lightly insulated Aluminum
conductor.

Cross Section Current Rating 2 Conductors 3or 4 Conductors

(mm2) (amp) 1- phase(volt) three phase (volt)
2.5 18 22 17.3
4 27 19.9 15.7
6 42 20.6 16.2
10 58 17.1 12.5
16 78 14.3 11.2
25 101 13.5 9.3
35 117 9.7 7.6
50 156 9.1 7.2
70 187 7.8 6.2
95 245 7.6 6.0
120 280 6.9 5.5
150 327 6.4 5.0
185 374 5.9 4.7
240 436 5.3 4.2
300 514 4.4 3.4

Fuse Rates Compared to wire-Area

Fuse rates as compared to cross-sectional area of wires should be in accordance with the values
Given below: (For PVC and Rubber Insulated Wire)

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 F U S E
A R E A(mm2) Current(Amps) Silver diameter(mm) Lead diameter(mm)
1.5 10 0.24 1.0
2.5 15 0.37 1.3
4 20 0.39 1.5
6 25 4.46 1.8
10 35 0.60 2.4
16 60 0.77 3.7
25 80 0.97 --
25 100 1.05 --
60 125 1.15 --
70 160 1.30 --
95 200 1.53 --
120 225 -- --
150 260 -- --
185 300 -- --

Circuit Breaker Ratings

Note 1. The current rating of standard circuit breakers are:

10A, 16A, 20A, 25A, 35A, 50A, 63A, 80A, 100A, 125A, 160A, 200A, 250, 355A,
425A, 500A, 600A, 710A, 850A.

The maximum current rating of PVC insulated single core copper cables and the rating of the
protecting circuit breakers is given below.

Nominal Cross-section (mm2) Current Ratings (A) Breaker Rating (A)

1 12 10
1.5 16 16
2.5 21 20
4 27 25
6 35 35
10 48 50
16 65 63
25 88 80
35 110 100
50 140 125
70 175 160
95 210 200

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 120 250 250

3.6. Voltage Drop Calculation

The resistance of a conductor increases as the length increases and / or the cross sectional area
decreases. Associated with an increased resistance is drop in voltage, which means that a load at the
end of along thin cable will not have the full supply voltage available.

V = Vc + VL
-The IEE regulation require that the voltage drop Vc shouldn’t be so excessive that equipment
doesn’t function safely. The drop of not more than 4% (IEE)

Therefore for single phase 230v, the drop should not exceed 4% of 230v = 9.2v

For three phase 400v, the voltage drop should not exceed 4% of 400v = 16v

The drop of not more than 2.5% (EEPCO)

Single phase It should be less than 2.5% of 220v = 5.5v

Three phase It should be less than 2.5% of 380v = 9.5v

V = V – VL = R x VL / R – total resistance in the circuit conductor

Ri =  L  - resistivity of conductor material

A L - length from source to load
A - Cross-sectional area of the conductor
Ri - resistivity per unit length

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 V = 2x LxRi x IL

V = 2x xLx IL for pure resistive load

A
V = 2x xLx IL x cos for reactive V = 2xL x  x P , V = 220v
A VxA

For three phase,

V = L x  x P V=380v
AxV

The above formula can be summarized as follows:

Voltage Drop For dc or single phase, power For three phase ac with power
factor = cos factor = cos
When the current I is known V = 2x xLx IL x cos V = 1.73xLx IL x cos
A A
When the power P is known V = 2x xLxP V = xLxP
AxV AxV

Example-1- Consider the installation circuit consisting of three lighting points:

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 I1 = i1 + i2 + i3 voltage drop will be:

V = I1 (2xL1xR1) + I2(2xL2xR2) + I3(2xL3xR3), R1=R2=R3 -- resistance per unit length

V = 2x x (I1 xL1) + I2xL2 + I3xL3

A
In practice the highest voltage drop is calculated for the most distant load.

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