CableCALC BS 7671 Operating Manual

CableCALC Pro BS 7671 - Operating Manual
www.cablecalcpro.co.uk
CableCALC Pro BS 7671 Operating Manual

Version 2012
This reference manual contains examples on how to use CableCALC Pro BS electrical software which is used for designing electrical installations in accordance with British Standard 7671:2008 (IEE Wiring Regulations 17th Ed.) and IEC 60364. Table of contents 1. Example 1: Flat two-core, Clipped direct .............................................................. 3 1.1 1.2 Problem ........................................................................................................... 3 Solution ........................................................................................................... 3 Cable ........................................................................................................ 3 Load ......................................................................................................... 3 Supply ...................................................................................................... 5 Correction ................................................................................................ 6 Protection ................................................................................................. 6 Phase conductor ....................................................................................... 7 Earth conductor ........................................................................................ 7
1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.3 1.3.1 1.3.2 2 2.1 2.2
Results ............................................................................................................. 7
Example 2: Single-core thermosetting, In trunking ............................................... 8 Problem ........................................................................................................... 8 Solution ........................................................................................................... 8 Cable ........................................................................................................ 8 Load ......................................................................................................... 8 Supply ...................................................................................................... 8 Correction ................................................................................................ 9 Protection ............................................................................................... 10 Phase conductor ..................................................................................... 10 Earth conductor ...................................................................................... 10
2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3 2.3.1 2.3.2 3 3.1 3.2
Results ........................................................................................................... 10
Example 3: Direct buried ..................................................................................... 11 Problem ......................................................................................................... 11 Solution ......................................................................................................... 11 Cable ...................................................................................................... 11 1
3.2.1
P0301-DC-01-002_Cablecalc BS7671-Operating Manual.Docx
CableCALC Pro BS 7671 - Operating Manual 3.2.2 3.2.3 3.2.4 3.2.5 3.3 3.3.1 3.3.2 4 4.1 4.2
Load ....................................................................................................... 11 Supply .................................................................................................... 11 Correction .............................................................................................. 12 Protection ............................................................................................... 13 Phase conductor ..................................................................................... 13 Earth conductor ...................................................................................... 13
Results ........................................................................................................... 13
Example 4: Motor circuit ..................................................................................... 14 Problem ......................................................................................................... 14 Solution ......................................................................................................... 14 Cable ...................................................................................................... 14 Load ....................................................................................................... 14 Supply .................................................................................................... 15 Correction .............................................................................................. 15 Protection ............................................................................................... 15 Phase conductor ..................................................................................... 16 Earth conductor ...................................................................................... 16
4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.3 4.3.1 4.3.2 5
Results ........................................................................................................... 16
Support and technical services ............................................................................. 17
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1. Example 1: Flat two-core, Clipped direct

1.1 Problem
A 230 V single-phase radial circuit is to be run in flat two-core (with cpc) 70 C thermoplastic insulated and sheathed cable having copper conductors clipped direct and not grouped with the cables of other circuits. The circuit is to be protected by a BS 88-2.2 gG fuse against overload and short circuit. If Ib = 42 A, l = 27 m, ta = 40 C, Ze = 0.35 and the short-circuit current at the point of supply is 4 kA determine the nominal rating of the fuse and minimum conductor cross-sectional area if the voltage drop is not to exceed 4 % of the nominal voltage.
1.2 Solution
By hand, the iterative process of solving this example can take hours. Using the software it is solved within minutes, or even seconds. Data entry is flexible in that it can be entered into the program by the user in any order. However, it is best to start with the cable data and the installation method as this affects other outputs such as the correction factor calculations.
1.2.1 Cable
From the Cable tab set the control values according to Table 1. Set the Installation method to C Clipped Direct. See Figure 1.
Table 1. Example 1 Cable tab control values
Control Name Phases Cores Material Armour Insulation
Value 1 Multi-core Copper Armoured Thermoplastic Flat (70 C)
1.2.2 Load
Next go to the Load tab and set the load current to 42 A. As per Table 2 the circuit arrangement is Radial, Power Factor is 1 and Efficiency is 100 %.
Table 2. Example 1 Load tab control values
Control Name Power/Current Amps Efficiency Power Factor Circuit Arrangement
Value Current 42 A 100 % 1 Radial
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Figure 1. Example 1 - Cable user inputs
Figure 2. Example 1 - Load user inputs
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1.2.3 Supply
From the supply tab set the Voltage Drop (%) to 4 %, Length = 27 m, Upstream Fault Level = 4 kA, Impedance, Ze = 0.35 .
Table 3. Example 1 Supply tab control values.
Control Name Voltage ph-e Voltage Drop Use VD? Length Upstream Fault Level Impedance, Ze Frequency System Grounding
Value Comments 1 and 3 supply default is 230 Vpn and 400 Vpp. 230 V 4% True 27 m 4 kA 0.35 50 Hz TN-C-S
Notes: - Right-click the Impedance, Ze control for information on typical source impedance values to be used. - Although in reality the upstream fault level and the source impedance are related by Ohms Law they are usually specified as separate values.
Figure 3. Supply - user inputs
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1.2.4 Correction
Go to the Correction tab and press the Ambient temperature, Ca button to open the appropriate calculation program. Set the ambient temperature to 40 degrees Celsius. This results in a calculated ambient temperature correction factor equal to 0.87.
Figure 4. Example 1 - Ambient temperature correction factor Ca calculation
1.2.5 Protection
Go to the Protection tab and select the type of protection device. Open (+)Cartridge Fuses (+)HRC Fuse (BS 88) 50 A.
Table 4. Example 1 protection tab control values
Control Name Protection provided
Value Overload and Short-circuit protection
Comments Design current for sizing cables, Ib when protection provided is (a) Overload and Shortcircuit protection Ib = Nominal current of protective device In; or (b) Short-circuit protection only Ib = Load current.
Circuit protective device Short-circuit clearing time Earth fault clearing time
Cartridge Fuses\HRC Fuse (BS 88)\50 A Accurate values obtained from manufacturers 0.5 s curves based on calculated fault currents. 0.5 s
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Figure 5. Example 1 - Protection user inputs
1.3 Results
1.3.1 Phase conductor
The minimum conductor size required is 10 mm2 which has a tabulated currentcarrying capacity of 64 A with an effective current-carrying capacity (de-rated) of 55.7 A. The actual voltage drop is 2.08 %. Note for small conductor sizes the short-circuit performance would be the main influence on the minimum conductor size requires if the short-circuit clearing time and/or the upstream fault level were greater.
1.3.2 Earth conductor

The standard earth conductor size for this type and size of cable is 4 mm2. By default the program specifies a 10 mm2 earth cable size based on Table 54-7 from BS 7671. In many cases a smaller earth cable size can be used. The user should manually specify the earth cable size to be used and check for compliance with earth fault loop impedance and short-circuit performance. In this case the standard 4 mm2 earth cable is compliant.
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2 Example 2: Single-core thermosetting, In trunking

2.1 Problem
A 230 V single-phase circuit is to be run in single-core 90 C thermosetting cables having copper conductors, in trunking with five other similar circuits. The circuit is to be protected by a BS 88-2.2 gG fuse against overload and short-circuit. If Ib = 38 A, l = 90 m, ta = 45 C, Ze = 0.8 and the power factor of the load is 0.8 lagging and the short-circuit current at the point of supply is 6 kA determine the minimum conductor cross-sectional area if the voltage drop is not to exceed 2.5 % of the nominal voltage.
2.2 Solution
2.2.1 Cable
From the Cable tab set the control values according to Table 5. Set the Installation method to B Enclosed in conduit on a wall or in trunking.
Value 1 Single-core Copper Non-armoured Thermosetting (90 C)
2.2.2 Load
Next go to the Load tab and set the load current to 38 A. As per Table 6 the circuit arrangement is Radial, Power Factor is 0.8 and Efficiency is 100 %.
Value Current 38 A 100 % 0.8 Radial
2.2.3 Supply
From the supply tab set the Voltage Drop (%) to 2.5 %, Length = 90 m, Upstream Fault Level = 6 kA, Impedance, Ze = 0.8 .
8

Control Name Voltage ph-e Voltage Drop Use VD? Length Upstream Fault Level Impedance, Ze Frequency System Grounding
Value 230 V 2.5 % True 90 m 6 kA 0.8 50 Hz TN-C-S
2.2.4 Correction
Go to the Correction tab and press the Ambient temperature, Ca button to open the appropriate calculation program. Set the ambient temperature to 45 degrees Celsius which results in a calculated correction factor Ca = 0.87. Press the Grouping, Cg button and set the no. of circuits to 6 which results in a calculated correction factor Cg = 0.57. The overall correction factor (displayed) is equal to Ca * Cg = 0.496. Note to reset all correction factors, right-click Overall Correction Factor and select Reinitialise to Default Value.
Figure 6. Example 2 Correction factor for Grouping, Cg. Note that the total No. of (grouped) circuits includes the cable being calculated (1) plus (+) the five (5) other circuits.
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2.2.5 Protection
Table 7. Example 2 Protection tab control values.
Control Name Protection provided Circuit protective device Short-circuit clearing time Earth fault clearing time
Value Overload and Short-circuit protection Cartridge Fuses\HRC Fuse (BS 88)\40 A 1s 1s
2.3 Results
The minimum conductor size required is 25 mm2 which has a tabulated currentcarrying capacity of 133 A with an effective current-carrying capacity (de-rated) of 66 A. The actual voltage drop is 2.41 %.

By default the program specifies a 16 mm2 earth cable size based on Table 54-7 from BS 7671. In many cases a smaller earth cable size can be used. The user should manually specify the earth cable size to be used and check for compliance with earth fault loop impedance and short-circuit performance. In this case a 6 mm2 earth cable satisfies earth fault loop and short-circuit performance requirements.
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3 Example 3: Direct buried

3.1 Problem
A 400 V three-phase circuit is to be run in multi-core 90 C thermosetting and sheathed cables having copper conductors and is protected against overload and shortcircuit by a 40 A BS 88-2.2 gG fuse. The cable will be direct buried at a depth of 0.5 meters across a brown field site where the soil conditions are not known. If Ib = 35 A, l = 55 m, soil ambient temperature ta = 25 C, Ze = 0.35 and the power factor of the load is 0.9 lagging and the short-circuit current at the point of supply is 6 kA determine the minimum conductor cross-sectional area if the voltage drop is not to exceed 2.5 % of the nominal voltage.
3.2 Solution
3.2.1 Cable
From the Cable tab set the control values according to Table 5. Set the Installation method to D Direct in ground or in ducting in ground, in or around buildings.
Value 3 Multi-core Copper Armoured Thermosetting (90 C)
3.2.2 Load
Next go to the Load tab and set the load current to 35 A. As per Table 6 the circuit arrangement is Radial, Power Factor is 0.9 and Efficiency is 100 %.
Value Current 38 A 100 % 0.9 Radial
3.2.3 Supply
From the supply tab set the Voltage Drop (%) to 2.5 %, Length = 55 m, Upstream Fault Level = 6 kA, Impedance, Ze = 0.35 .
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Control Name Voltage ph-ph Voltage Drop Use VD? Length Upstream Fault Level Impedance, Ze Frequency System Grounding
Value 400 V 2.5 % True 55 m 6 kA 0.35 50 Hz TN-C-S
3.2.4 Correction
Go to the Correction tab and press the Depth of burial, Cb button. Set the depth of burial to 0.5 metres which results in a calculated correction factor Cb = 1.04. Set the correction factor for Ambient temperature, Ca to soil ambient temperature of 25 degrees Celsius which results in a calculated correction factor Ca = 0.96. The soil conditions are not known, but because of the nature of the site the soil thermal conductivity is assumed to be poor. The tabulated current-carrying capacities for buried cables by default assume 2.5 K.m/W; which is poor. Therefore the correction factor for thermal resistivity of soil (Cs) can remain equal to 1. The overload factor for BS 88-2.2 fuse is 1.45; thus overload for buried cables (Cc) is set automatically by the program equal to 0.9 (Regulation 433.1.4 in BS 7671:2008).
Figure 7. Example 3 Correction factor for Depth of burial, Cb. Note correction factor >1 (i.e. effective current-carrying capacity increased) for shallower (than default 0.8 m) depth of burial.
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3.2.5 Protection
Value Overload and Short-circuit protection Cartridge Fuses\HRC Fuse (BS 88)\40 A 1s 1s
3.3 Results
The minimum conductor size required is 10 mm2 which has a tabulated currentcarrying capacity of 58 A with an effective current-carrying capacity (de-rated) of 52.1 A. The actual voltage drop is 2.48 %.

By default the program specifies a 10 mm2 earth cable size based on Table 54-7 from BS 7671. In many cases a smaller earth cable size can be used. The user should manually specify the earth cable size to be used and check for compliance with earth fault loop impedance and short-circuit performance. A 6 mm2 earth cable satisfies earth fault loop and short-circuit performance requirements.
13
4 Example 4: Motor circuit

4.1 Problem
A 400 V three-phase induction motor has a (mechanical power) rating of 10 kW at a power factor of 0.85 lagging at an efficiency of 90 %. If the motor is subject to frequent stopping and starting and the connection between a direct-on-line starter and the motor terminals is a multi-core armoured thermosetting cable with copper conductors, installed in free air, what is the minimum conductor cross-section area required?
4.2 Solution
Regulation 552.1.1 (BS 7671:2008) requires that where a motor is intended for intermittent duty and for frequent starting and stopping account should be taken of the cumulative temperature rise effects on the cables feeding the motor. Furthermore, starting currents for Direct-On-Line starting (D.O.L.) can be between 5 and 8 times the full load current. CableCALC has settings which allow users to size cables for motors (between the starter and the motor terminals).
4.2.1 Cable
From the Cable tab set the control values according to Table 5. Set the Installation method to D Direct in ground or in ducting in ground, in or around buildings.
Value 3 Multi-core Copper Armoured Thermosetting (90 C)
4.2.2 Load
Next go to the Load tab and set the load power to 10 kW. The circuit arrangement is D.O.L. Motor, Power Factor is 0.85 and Efficiency is 90 %.
Control Name Power/Current Power Efficiency
Value Power 10 kW 90 % 14
CableCALC Pro BS 7671 - Operating Manual Power Factor 0.85 Circuit Arrangement D.O.L. Motor
4.2.3 Supply
From the supply tab set the Length = 25 m.
Control Name Voltage ph-ph Voltage Drop Use VD? Length Upstream Fault Level Impedance, Ze Frequency System Grounding
Value 400 V False 25 m 6 kA 0.35 50 Hz TN-C-S
4.2.4 Correction
Set the correction factor for Ambient temperature, Ca to ambient ambient temperature of 35 degrees Celsius which results in a calculated correction factor Ca = 0.96.
4.2.5 Protection
Go to the Protection tab and select the type of protection device. Open (+)Miniature Circuit Breaker (MCB) (+)Type C (BS EN 60898) 20 A.
Value Short-circuit protection only Miniature Circuit Breaker (MCB)\Type C (BS EN 60898)\20 A 0.25 s 0.25 s
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4.3 Results
The minimum conductor size required is 2.5 mm2 which has a tabulated currentcarrying capacity of 33 A with an effective current-carrying capacity (de-rated) of 31.7 A. Note the minimum phase conductor size is sensitive to the short-circuit fault clearing time (motors are typically protected from thermal overload).

The earth cable should have a minimum cross-sectional area of 1.5 mm2.
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5 Support and technical services

Electrotechnik are able to offer extended software and technical support. Visit our company homepage www.cablecalcpro.co.uk.
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CableCALC Pro BS 7671 - Operating Manual

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P0301-DC-01-002_Cablecalc BS7671-Operating Manual.Docx

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.3 4.3.1 4.3.2 5

Support and technical services ............................................................................. 17

CableCALC Pro BS 7671 - Operating Manual

1. Example 1: Flat two-core, Clipped direct

Control Name Phases Cores Material Armour Insulation

Value 1 Multi-core Copper Armoured Thermoplastic Flat (70 C)

Control Name Power/Current Amps Efficiency Power Factor Circuit Arrangement

Value Current 42 A 100 % 1 Radial

CableCALC Pro BS 7671 - Operating Manual

Figure 1. Example 1 - Cable user inputs

Figure 2. Example 1 - Load user inputs

CableCALC Pro BS 7671 - Operating Manual

Figure 3. Supply - user inputs

CableCALC Pro BS 7671 - Operating Manual

Figure 4. Example 1 - Ambient temperature correction factor Ca calculation

Control Name Protection provided

Value Overload and Short-circuit protection

CableCALC Pro BS 7671 - Operating Manual

Figure 5. Example 1 - Protection user inputs

1.3.2 Earth conductor

CableCALC Pro BS 7671 - Operating Manual

2 Example 2: Single-core thermosetting, In trunking

Control Name Phases Cores Material Armour Insulation

Value 1 Single-core Copper Non-armoured Thermosetting (90 C)

Control Name Power/Current Amps Efficiency Power Factor Circuit Arrangement

Value Current 38 A 100 % 0.8 Radial

CableCALC Pro BS 7671 - Operating Manual

Value 230 V 2.5 % True 90 m 6 kA 0.8 50 Hz TN-C-S

CableCALC Pro BS 7671 - Operating Manual

2.3.2 Earth conductor

CableCALC Pro BS 7671 - Operating Manual

3 Example 3: Direct buried

Control Name Phases Cores Material Armour Insulation

Value 3 Multi-core Copper Armoured Thermosetting (90 C)

Control Name Power/Current Amps Efficiency Power Factor Circuit Arrangement

Value Current 38 A 100 % 0.9 Radial

CableCALC Pro BS 7671 - Operating Manual

Value 400 V 2.5 % True 55 m 6 kA 0.35 50 Hz TN-C-S

CableCALC Pro BS 7671 - Operating Manual

3.3.2 Earth conductor

CableCALC Pro BS 7671 - Operating Manual

4 Example 4: Motor circuit

Control Name Phases Cores Material Armour Insulation

Value 3 Multi-core Copper Armoured Thermosetting (90 C)

Control Name Power/Current Power Efficiency

P0301-DC-01-002_Cablecalc BS7671-Operating Manual.Docx

Value 400 V False 25 m 6 kA 0.35 50 Hz TN-C-S

CableCALC Pro BS 7671 - Operating Manual

4.3.2 Earth conductor

CableCALC Pro BS 7671 - Operating Manual

5 Support and technical services

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