TECHNICAL

STUDENTTOPIC MINIMISING VOLTAGE DIFFERENCES

Short guide to working

In the first of two Ask any electrician about the required cross-sectional
areas of cables for standard circuits and the answer
articles, Bill Allan you receive will probably be along the lines of: “1mm2
looks at the or 1.5 mm2 for lighting circuits and 2.5 mm2 for
socket-outlet circuits.”
correct method in Indeed these are the commonly used rule of
cross-sectional thumb sizes.
However, those who undertake electrical
work, a job that installation work need to understand the procedure
requires a head for selecting the correct cross-sectional area of a
cable for a particular use.
for calculations It is the intention of this article to explain simply
and a steady how to select the correct cross-sectional area of
cables with particular single-phase loads in mind.
hand I’ll refer to the tables in Appendix 4 of BS 7671,
although these tables are reproduced in Appendix 6
of the IEE On Site Guide. We’ll assume that the
overcurrent protective device will be providing fault
current and overload current which is the normal
situation.
Calculating the right size
There are five steps to calculating the right size of
cable for a particular load. These are as follows:
1 Calculate the design current (Ib). This is the normal
current drawn by the load. It is usually determined
as follows:
Watts
Ib =
Volts
2 Select the type and current rating of the
overcurrent device (In).
Grouping, Cg
This factor is found by reference to Table 4B1 in
Appendix 4. Table 4B2 is used where mineral
insulated cables are installed on perforated cable tray.
Thermal insulation, Ci
Where a cable is in contact with thermal insulation on
one side only, the current-carrying capacity of the
cable should be calculated using Reference Method
4, which is described in Appendix 4 (Table 4A) of BS
7671.
Where a cable is totally surrounded by thermal
insulation for a distance greater than 0.5 metres, the
current-carrying capacity should be taken, in the
absence of further information, as 0.5 times the
current-carrying capacity for that cable when using
Installation Method 1 (open and clipped direct).
Where a cable is totally surrounded by thermal
insulation for a distance of 0.5 metres or less, Table
52A in BS 7671 gives derating factors which must be
applied.
Rewireable fuse (BS 3036) factor, Cr
Where a rewireable fuse to BS 3036 is used, a further
correction factor of 0.725 is applied, due to the poor
fusing factor of rewireable fuses.
How to apply correction factors
These correction factors are applied as divisors to the
nominal current rating of the overcurrent protective
device (In), to obtain the tabulated current, It. For
example, in the worst possible situation where all four
factors are applied, the formula would look like this:

3 Apply the relevant correction factors to obtain the In

tabulated current (It). It > ––––––––––––––
Correction factors are applied to situations which Ca x Cg x Ci x Cr
inhibit a cable from dissipating its heat caused by
the normal flow of current through it. Therefore, The more correction factors we apply, the larger the
the following correction factors, if applicable, are value of It will be and hence the larger the size of
applied: cable we will require. Consequently, it is
advantageous to avoid having to apply correction
Ambient temperature, Ca factors where possible by, such measures as,
This factor is obtained from Table 4C1 (or Table 4C2 if avoiding grouping of cables and avoiding contact
a rewireable fuse to BS 3036 is used) in Appendix 4 of with thermal insulation.
BS 7671. However the formula given above is based on the
assumption that the conditions requiring the
application of correction factors apply simultaneously
to the same part of the cable along its route.
Fig 1 Thermal Ambient Where particular correction factors are appropriate
Grouping insulation temperature to different parts of the cable along its route, each part
Factor Factor Factor can be treated separately. Alternatively, only the
(0.65) (0.5) (0.94) correction factor (or combination of factors)
Consumer for distances
over 0.5 metres Load applicable to the worst situation along the cable route
unit
(0.725) can be applied to the whole route. (See Item 6.4 of
BS 3036 fuse
Appendix 4 in BS 7671)

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out cable sizes See overleaf for
Student Activities

For example, in Fig 1, a cable which is protected by a

BS 3036 rewireable fuse is first grouped together with
other cables, then it is totally surrounded by thermal
insulation for a distance of more than 0.5 metres. Then
finally it is run through an area with a high ambient
temperature. As the BS 3036 fuse affects the whole cable
run, Ct must be applied. However, there is no need to
apply the other three factors as the worst factor alone will
be sufficient. Let’s take the grouping factor to be 0.65, the
thermal insulation factor to be 0.5 and the ambient
temperature factor as 0.94, as indicated in Fig 1. In this
case, only Cr = 0.725 and Ci = 0.5 need to be applied.
The factors for grouping and ambient temperature are
0.65 x 0.94 = 0.61. As the factor for thermal insulation is
lower (0.5), this is the only factor used for the conditions
along the cable run.
Worked example
1 A 6kW load is to be supplied at 230 V by a PVC sheathed and
insulated twin and cpc copper cable, 8 metres in length. The cable is
clipped on the surface through an area with an ambient temperature
of 40°C and is grouped with three other cables of similar size and
loading. The protection is by means of a BS 3036 fuse. Calculate the
minimum cable size required (it is assumed in this example that all the
correction factors need to be applied).
Answer
W 6000
Design current, Ib = –––– = ––––– = 26 amps
V 230

In Size of BS 3036 fuse required = 30 amps (In )

It > ––––––
Ci x Cr In
Tabulated current, It > –––––––––––––––
4 The current-carrying capacity of the cable (which is correction factors
termed Iz) is then selected from the appropriate table
in Appendix 4 of BS 7671. Iz should be at least equal From Table 4C2, Ca = 0.94
to or slightly greater than the tabulated current, It.
From Table 4B1, (4 circuits, Method 1)
5 Calculate the voltage drop to ensure that it is not Cg = 0.65
excessive. Regulation 525-01-02 states that the
voltage drop from the origin of the supply to the Correction factor for BS 3036 fuse = 0.725
furthest point in the installation must not exceed four
per cent of the supply voltage when the conductors In
are carrying full load current. The tables in Appendix 4 It > ––––––––––––––
have a voltage drop section in which the millivolt per Ca x Cg x Cr
amp per metre (mv/a/m) of a particular cable may be
obtained. The voltage drop is calculated from: In
> ––––––––––––––––
Volts drop = 0.94 x 0.65 x 0.725

mv/a/m x design current, Ib x length of run in metres, L > 67.7 amps

–––––––––––––––––––––––––––––––––––––––––––––––
1000 From Table 4D5A (Reference Method 1, column 4), select 16 mm2 cable
which takes 85 amps.
As four per cent of the nominal 230 volts single-phase
supply voltage is 9.2 volts, this figure must not be Check volts drop from Table 4D2B (column 3).
exceeded for single-phase supplies.
mV/Am x Ib x L
volts drop = –––––––––––––
Conclusion 1000
If you need some practice in calculating the right size
for cables, you might try the examples in the Student 2.8 x 26 x 8
Activities section. In the next issue, we’ll consider this = –––––––––
topic some more. Further information can be obtained 1000
from Appendix 4 of BS 7671, and IEE Guidance Note 6,
Protection Against Overcurrent. For a more simplified = 0.58 volts (satisfactory)
approach, Appendix 6 of the IEE On Site Guide should
be consulted.

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 TECHNICAL
STUDENTTOPIC MINIMISING VOLTAGE DIFFERENCES
Guide to working out ca
In part two in In the previous issue of The Competent Person
magazine, we considered the five basic steps for
this series, working out the correct size of cable for a particular
load. Due to the importance of this subject, we ought
Bill Allan to consider it further. In particular, we’ll look at the
continues his cross-sectional areas of neutral conductors and
protective conductors.
look at the
Co-ordination between conductor
basic steps
and provides and protective device
Regulation 433-02-01 in Section 433 contains the
examples to requirements for the relationship between the
conductor and the overcurrent device which protects it.
test your The terms included in this Regulation are:
knowledge Ib = the load current
In = the nominal current rating of the overcurrent
protective device
Iz = the current-carrying capacity (that is, the current
rating) of the conductors
I2 = the current causing effective operation of the
overcurrent protective device.
That being said, Regulation 433-02-01 can be
summarised as follows:
(i) In > Ib
(ii) Iz > In
(iii)1.45 x Iz > I2
Regulation 433-02-02 states that, for the following
devices, compliance with condition (ii) above results
in compliance with condition (iii). In other words, for
the following devices, I2 is deemed to be less than
1.45 x Iz:
• type (gG) fuses to BS 88-2.1
• fuses to BS 88-6
• fuses to BS 1361
• circuit-breakers to BS EN 60898
• circuit-breakers to BS EN 60947-2
• RCBO to BS EN 61009-1
Regulation 433-02-03 concerns rewireable fuses to
BS 3036 and may be summarised like this:
0.725 x Iz > In
Student 1 Study Regulation 433-02-01 of BS 7671 and
summarise the requirements regarding the co-
Activities ordination between conductor and protective device.
2 Study Section 524-02 of BS 7671 and summarise
the requirements regarding the cross-sectional area
of neutral conductors.
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Cross-sectional areas of neutral
conductors
Section 524 of BS 7671 contains general
requirements for cross-sectional areas of phase
conductors and neutral conductors. In single-phase
circuits, the cross-sectional area of the neutral
conductor must not be less than that of the phase
conductor. In three-phase circuits, the size of neutral
conductors may be reduced provided that the
designer has assessed that the current in the neutral
conductor will be less than that in the phase
conductors. However this reduction of the neutral
conductor is becoming less common due to the
harmonic content of modern electrical loads. In any
case, the practice is not permitted for discharge
lighting circuits.
Cross-sectional area of protective
conductors
The requirements for determining the cross-sectional
areas of protective conductors are found in Section
543 of BS 7671. The first regulation in this Section,
Regulation 543-01-01 contains two basic methods for
determining the cross-sectional area of protective
conductors:
1 It can be selected using the adiabatic equation, or
2 It can be selected using Table 54G.
1 The adiabatic equation
The adiabatic equation is given in Regulation 543-01-
03 and looks like this:
I2 t
S = –––––
k
where, S = the cross-sectional area of the protective
conductor
I = the fault current
t = the operating time of the overcurrent device
corresponding to the fault current
k = a factor which takes account of the resistivity,
temperature coefficient and heat capacity of the
conductor material
3 Study Section 543-01 of BS 7671 and summarise
the requirements regarding the cross-sectional area
of protective conductors.
4 Use the adiabatic equation to determine the
minimum cross-sectional area of a circuit protective
able sizes 2
This might look quite daunting but a worked example 2 Table 54G
is the best way to show how it works.
If the adiabatic equation looks like too much trouble, then the good news is that
you can use Table 54G of BS 7671.
Worked example
Table 54G
Use the adiabatic equation to determine the Minimum cross-sectional area of protective conductor in relation to
minimum cross-sectional area of a circuit the cross-sectional area of associated phase conductor
protective conductor suitable for use on a radial
circuit protected by a 30 amp fuse to BS 3036. Cross-sectional area Minimum cross-sectional area of the
The 230 volt circuit is wired in single-core 70° C of phase conductor, corresponding protective conductor
PVC insulated cables with copper conductors, S
which are installed in steel conduit. The cross-
sectional area of the phase and neutral If the protective If the protective
conductors is 4 mm2. The earth fault loop conductor is of the conductor is not of
impedance Zs is 1.44 ohms. same material as the the same material as
phase conductor the phase conductor
Answer (mm2) (mm2) (mm2 )
V 230 k1
Fault current, If = –––– = –––– = 160 amps. S < 16 S –– x S
Zs 1.44 k2

The disconnection time, t, is found by reference k1

16 < S < 35 16 –– x 16
to the appropriate time/current characteristic of k2
a 30 amp BS 3036 fuse. This is found in Fig.
3.2A in Appendix 3 of BS 7671. These S k1 S
time/current curves make use of logarithmic S > 35 –– –– x ––
scales, which enable large scales to be used in 2 k2 2
a relatively small area. The disconnection time is
approximately 0.8 seconds. The value of k is
obtained from Table 54C of BS 7671 and is 115. where: k1 is the value of k for the phase conductor, selected from Table
Now the adiabatic equation can be used as 43A in Chapter 43 according to the materials of both conductor and
follows: insulation.

k2 is the value of k for the protective conductor, selected from Tables 54B,
I2 t 160 2 x 0.8
S = –––––––– = ––––––––––– = 1.24 mm2 54C, 54D, 54E or 54F, as applicable.
k 115

Note
It is only the top line which is
square rooted not the whole equation.
Reference to Table 54G shows that, where the associated phase conductor has a
cross-sectional area up to and including 16 mm2, the protective conductor can be
of the same cross-sectional area. In the worked example above, the cross-
sectional area of the associated phase conductor is 4mm2. This means that, using
Table 54G would require the protective conductor also to have a cross-sectional
area of 4 mm2. This size is clearly considerably larger than the 1.24 mm2 which
was selected using the adiabatic equation method. It is however much quicker and
easier to use Table 54G.

conductor suitable for use on a radial circuit Conclusion

protected by a 20 amp fuse to BS 88-2.1. The 230
volt circuit is wired in 70°C PVC insulated and
sheathed flat cable with a protective conductor
(copper conductors). The earth fault loop
impedance Zs is 1.53 ohms. (Assume k to be 115).
Student Activities (left) contains more examples, together with the answers, if you
need the practice.
Answers to Student Activities from Issue 2:
1, 0.60; 2, 0.87; 3, 0.98; 4, 0.55; 5, Column 2; 6, 8.69 amps; 7, 15 amps.

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