SELECTION OF LOW VOLTAGE CABLES

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 Different Types of Cables

• There are different types of cables in the Low Voltage Power supply. Those are categorized
based on the materials used for the construction of the cables and the voltage rating of the
cables.

• The different types of cables used nowadays based on the type of main conductive materials
used for construction of cables are

(a) Copper cables (b) Aluminum cables

• The different types of cables based on the type of insulation materials:

(a) Rubber insulated cables

(b) Paper insulated cables.
(c) PVC insulated cables.
(d) XLPE insulated cables.
(e) Mineral insulated cables.

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 MAXIMUM OPERATING TEMPERATURE FOR DIFFERENT TYPES OF CABLE INSULATION

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 Different Types of Cables
1. Notation of cables in common practice.

(a) Cu/PVC – PVC insulated copper cable.

(b) Cu/PVC/PVC – PVC sheathed, PVC insulated copper cable.
(c) Cu/XLPE/PVC – PVC sheathed, XLPE insulated copper cable
(d) Cu/XLPE/SWA/PVC – same as above but with “steel wire armour” for additional mechanical
protection.

2. (a) Cu/PVC cables are used for earth cables in Sri Lanka. But it can be used for power cables also.

(b) Cu/PVC/PVC cables are used for final circuits such as light point wiring, socket outlet wiring, etc.

(c) Cu/XLPE/PVC cables are used as main or sub power feeders within the building.

(d) Cu/XLPE/SWA/PVC are used as the main or sub power feeder especially.

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 Current Currying Capacity of Cables
• The current currying capacity of the cables depends on its ability to lose the heat produced
in it by the current it carries.

• The heat dissipation of the cables depends on the followings:

(a) The way / method of cable installation.

(b) The number of cables / circuits grouped together.
(c) The ambient temperature.

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 Different Types of Cables
Different types of cables based on the voltage ratings:
(a) Cables with a voltage rating of 300/500 V.
(b) Cables with a voltage rating of 450/750 V.
(c) Cables with a voltage rating of 600/1000 V.

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 DETERMINATION OF THE SIZE OF CABLE TO BE
USED

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 STEPS INVOLVED IN CABLE SIZING

• Step-1: Determination of design current (Ib).

• Step-2: Determination of the rated current of the protective device (In). In > Ib
• Step-3: Determination of the tabulated current of the cable (It) using the
following formula:

It > In /CaCcCdCfCgCiCs

Where,
Ca – Correction factor for ambient temperature.
Cc – Correction factor for circuits buried in the ground.
Cd – Correction factor for depth of burial.
Cf – Correction factor for semi-enclosed fuse to BS3036.
Cg – Correction factor for grouping.
Ci – Correction factor for thermal insulation.
Cs – Correction factor for thermal resistivity of the soil.

For cables installed above ground, Cs=Cd=Cc=1.

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 STEPS INVOLVED IN CABLE SIZING
• For cables installed above ground, Cs=Cd=Cc=1.
• For cables protected by any protective devices except semi-enclosed fuse to BS3036, Cf = 1.
• For cables protected by semi-enclosed fuse to BS3036, Cf = 0.725.
• For cables installed “in a duct in the ground” or “buried direct”, Cc = 0.9.

Step-4: Determination of the tabulated current of the cable (It) using the
following formula (if overload protection is not required):

It > Ib /CaCcCdCfCgCiCs

Where overload protection is not required, Cc=1.

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 Example: Consider a three phase with a design load (fundamental current) of 58A is to be installed
using a 4 core 90oC thermosetting insulated cable. The cable will be installed with three other
circuits on a perforated cable tray (method E or F) in an expected maximum ambient temperature of
35oC. The cable will be protected at its origin using a circuit breaker to BS EN60898-1.

Solution:
Case-1: Load does not produce 3rd harmonic currents.

Ib = 58A
So, rated current of the circuit breaker selected, In = 63A
It > In /CaCg
Ca = 0.96 from Table 4B1 and Cg = 0.77 from Table 4C1
It > 63 /(0.96*0.77)
It > 85.23A

So, the selected cable is 4C x 16mm2 Cu/XLPE/SWA/PVC (from Table 4E4A)

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
Prepared by: Eng. R. T. Paramanayagam,
B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
Prepared by: Eng. R. T. Paramanayagam,
B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
Prepared by: Eng. R. T. Paramanayagam,
B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 Case-2: Load produces an additional 3rd harmonic content (THDi = 20%)

If = 58A…………………..(fundamental current)
Since the 3rd harmonic current is 15 – 33%, the cable sizing will be based on the line current as
per Table 4Aa.

Ibh = 58*Ch ……(design current including the effect of 3rd harmonic current)

Ibh = 58*sqrt(12+0.22)
Ibh = 59.1A
So, rated current of the circuit breaker selected, In = 63A

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 It > In /CaCg*0.86
Ca = 0.96 from Table 4B1 and Cg = 0.77 from Table 4C1

It > 63 /(0.96*0.77*0.86)
It > 99.1A

From Table 4E4A, a 16mm2 cable has a tabulated current currying capacity of 99A, thus a rule-
based system may select a 25mm2 cable whereas a designer may exercise judgement and select
a 16mm2 cable.

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
Case-3: Load produces an additional 3rd harmonic content (THDi = 42%)

If = 58A…………………..(fundamental current)

Since the 3rd harmonic current is 33 –45%, the cable sizing will be based on the neutral current
as per Table 4Aa.

Ibn = 3*0.42*58 ……(neutral current due to the 3rd harmonic current)

Ibn = 73.08A
So, rated current of the circuit breaker selected, In = 100A

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 It > In /CaCg*0.86
Ca = 0.96 from Table 4B1 and Cg = 0.77 from Table 4C1

It > 100 /(0.96*0.77*0.86)

It > 157.3A

So, the selected cable is 4C x 35mm2 Cu/XLPE/SWA/PVC (from Table 4E4A)

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
Example:
An immersion heater rated at 230V, 3kW is to be installed using twin with protective conductor PVC
insulated and sheathed cable. The circuit will be running for much of its length in a roof space which is
thermally insulated with glass fiber. The roof space temperature is expected to rise to 50oC in summer,
and where it leaves the Consumer Unit and pass through a 50mm insulation filled cavity, the cable will
be bunched with seven others. Calculate the cross-sectional area of the required cable. Consider
reference method A for the installation.

Solution:
Ib = 3000/230 = 13.04A
So, a 16A MCB of Type-B can be selected to provide the circuit protection.
So, In = 16A
So, It = In/(Ca*Cg*Ci)
Ca = 0.71 (from Table 4B1)
Cg = 0.52 (from Table 4C1)
Ci = 0.88 (from Table 52.2)
So, It = 16/(0.71*0.52*0.88)
So, It = 49.24 A

So, the selected cable is 16mm2 twin cable (Table 4D5)

Prepared by: Eng. R. T. Paramanayagam,
B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
Prepared by: Eng. R. T. Paramanayagam,
B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 Example:

An immersion heater rated at 230V, 3kW is to be installed using single core

conductor PVC insulated and PVC sheathed cable. The circuit will be running in
PVC conduit embedded in a wall. The ambient temperature is expected to rise to
40oC in summer, the conduit is pass through a 50mm insulation filled cavity also,
and the cable will be bunched with two others. Calculate the cross-sectional area
of the required cable.

Solution:
Ib = 3000/230 = 13.04A
So, a 16A MCB of Type-B can be selected to provide the circuit protection.
So, In = 16A
So, It = In/(Ca*Cg*Ci)
Ca = 0.87 (from Table 4B1)
Cg = 0.70 (from Table 4C1)
Ci = 0.88 (from Table 52.2)

So, It = 16/(0.87*0.70*0.88)
So, It = 29.85 A

So, the selected cable is 2 x 1C x 4mm2 cable (Table 4D1A)

Prepared by: Eng. R. T. Paramanayagam,
B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
Prepared by: Eng. R. T. Paramanayagam,
B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
Example:
An immersion heater rated at 230V, 3kW is to be installed using single core conductor PVC insulated
and PVC sheathed cable. The circuit will be running in PVC conduit embedded in a wall. The ambient
temperature is expected to rise to 35oC in summer, and the cable will not be bunched with others.
Calculate the cross-sectional area of the required cable.
Solution:
Ib = 3000/230 = 13.04A
So, a 16A MCB of Type-B can be selected to provide the circuit protection.
So, In = 16A
So, It = In/(Ca*Cg*Ci)
Ca = 0.94 (from Table 4B1)
Cg = Not applicable
Ci = Not applicable
So, It = 16/0.94
So, It = 17.02 A

So, the selected cable is 2 x 1C x 1.5mm2 cable (Table 4D1A, single core cables)
The selected cable will be 1 x 2C x 2.5mm2 cable (Table 4D2A, multi core cables)
The selected cable will be 1 x 2C x 2.5mm2 Twin cable (Table 4D5, flat cables)

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 VOLTAGE DROP IN CABLES
 The (mV/A/m) value is given in the cable catalogues. These values correspond to the
maximum permitted normal operating temperature of the cables.

 The voltage drop is calculated by the following formula:

Vd = [(mV/A/m)*Ib*L]/1000 V

Were,

Vd = Voltage drop in Volts.

Ib = Design current in Ampere.
L = Length of the cable in meter.

 For cable having 16mm2 or less cross-sectional area, their inductances can be ignored and
(mV/A/m)r values are only tabulated.

 For cable having conductors greater than 16mm2 cross-sectional area, the impedance values
are given as (mV/A/m)z together with their resistive component (mV/A/m)r and reactive
component (mV/A/m)x .

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
VOLTAGE DROP IN CABLES

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 VOLTAGE DROP IN CABLES

 The tabulated voltage drop values (mV/A/m) can be corrected for temperature and power
factor.

 The correction for power factor can be done as follows:

 For cable having conductors of cross-sectional area 16mm2 or less,

Corrected mV/A/m = PF*(Tabulated (mV/A/m))

 For cable having conductors of cross-sectional area greater than16mm2,

Corrected mV/A/m = CosΦ*(Tabulated (mV/A/m)r) + SinΦ*(Tabulated(mV/A/m)x)

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 VOLTAGE DROP IN CABLES
 The tabulated voltage drop values (mV/A/m) can be corrected for temperature and power factor.

 The correction for temperature can be done as follows:

 For cable having conductors of cross-sectional area 16mm2 or less,

Corrected mV/A/m = Ct*(Tabulated (mV/A/m))

 For cable having conductors of cross-sectional area greater than16mm2,

Corrected mV/A/m = Ct*(Tabulated (mV/A/m)r) + (Tabulated(mV/A/m)x)

 Ct can be calculated using the following formula:

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 VOLTAGE DROP IN CUSTOMER’S INSTALLATION

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 VOLTAGE DROP IN CUSTOMER’S INSTALLATION
Example: Consider a three phase with a design load (fundamental current) of 58A is to be installed
using a 4 core 90oC thermosetting insulated cable. The cable will be installed with three other
circuits on a perforated cable tray (method E or F) in an expected maximum ambient temperature of
35oC. The cable will be protected at its origin using a circuit breaker to BS EN60898-1 and the route
length of the cables is 160m. Calculate the voltage drop.

Solution: (Case-1: Load does not produce 3rd harmonic currents)

Ib = 58A
The selected cable is 4C x 16mm2 Cu/XLPE/SWA/PVC.
So, (mV/A/m)r = 2.5 mV/A/m (from Table 4E4B)
L= 160 m.
Use the formula of Vd = [(mV/A/m)*Ib*L] / 1000 V So, 4C x 16mm2 Cu/XLPE/SWA/PVC cable is
Vd = (2.5*58*160) / 1000 V not suitable and hence we have to try with the
next higher size.
Vd = 23.2 V
Vd = (23.2*100) / 400 %
Vd = 5.8% (> 5% and thus, not acceptable as per Table 4Ab (i))

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
VOLTAGE DROP IN CUSTOMER’S INSTALLATION
Solution: (Case-1: Load does not produce 3rd harmonic currents)
Ib = 58A
The proposed cable is 4C x 25mm2 Cu/XLPE/SWA/PVC.
So, (mV/A/m)z = 1.65 mV/A/m (from Table 4E4B)
L= 160 m.
Use the formula of Vd = [(mV/A/m)*Ib*L] / 1000 V
Vd = (1.65*58*160) / 1000 V
Vd = 15.31 V
Vd = (15.31*100) / 400 %
Vd = 3.83% (< 5% and thus, acceptable as per Table 4Ab (i))
So, 4C x 25mm2 Cu/XLPE/SWA/PVC cable is the selected cable for this
application.

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 METHOD OF INSTALLATION

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 METHOD OF INSTALLATION

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 SIZING OF PROTECTIVE CONDUCTOR
 The cross-sectional area of every protective conductor, other than a protective bonding
conductor, shall be
 calculated in accordance with Regulation 543.1.3 or

 selected in accordance with Regulation 543.1.4

 If the protective conductor

 Is not an integral part of a cable, or
 Is not formed by conduit, ducting or trunking, or
 Is not contained in an enclosure formed by a wiring system,

The cross-sectional area shall be not less than 2.5mm2 copper equivalent if protection against
mechanical is provided, and 4mm2 copper equivalent if protection against mechanical is not
provided.

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 SIZING OF PROTECTIVE CONDUCTOR
 Calculation of the cross-sectional area of the protective conductor in accordance with Regulation
543.1.3:

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 SIZING OF PROTECTIVE CONDUCTOR
Example:

The fault current is 6kA and the disconnection time of the protective device is 0.2 sec. Calculate the size
of the protective conductor made of copper which is not integrated or bunched together with the power
cable.

Solution:

If = 10 kA
t = 0.2 s
k = 143

S = sqrt (60002*0.2)
143

S = 18.76 mm2

So, the selected Protective Conductor is 1C x 25mm2 Cu/PVC.

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 SIZING OF PROTECTIVE CONDUCTOR
 Selection of the cross-sectional area of the protective conductor in accordance with Regulation
543.1.4:

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 TYPES OF PROTECTIVE CONDUCTOR

 A protective conductor may consist of one or more of the following:

 A single core cable.
 A conductor in a cable.
 An insulated or bare conductor in a common enclosure with insulated live conductors.
 A fixed bare or insulated conductor.
 A metal covering, for example, the sheath, screen or amouring of a cable.
 A metal conduit, metallic cable management system or other enclosure or electrically
continuous support system for conductors.
 An extraneous-conductive-parts complying with Regulation 543.2.6.

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 THE MINIMUM CROSS-SECTIONAL AREA OF A BURIED EARTHING
CONDUCTOR

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
 TYPICAL EARTHING ARRANGEMENT

Prepared by: Eng. R. T. Paramanayagam,

B.Sc. Eng (Hons), CEng (SL), CMEngNZ, IntPE (SL), IntPE (NZ)
CABLE BENDING

 Cables can’t be bended as we want.

 There is something called minimum bending radius applicable for cables.

 This minimum bending radius may vary depends on cable size, cable construction, conductor
type, sheathing & insulation types, etc.
 The manufacturer’s recommendation must be followed for the minimum bending radius for
various types of cables.
 Generally, the minimum bending radius is given as 8 times the overall cable diameter for non-
armoured cables and 12 times the overall cable diameter for armoured cables.
 It is highly recommended to maintain the minimum bending radius suggested by the cable
manufacturer in order to avoid any property damages to the materials used for sheathing,
insulation as well as conductor.