WIRING DESIGN WORKSHOP

C A B L E

S I Z I N G

F U N D A M E N TA L S

Cable Sizing For Safe Power

System Based on IEC Standards
I r . H . P. L o o i ( m e k t r i c o n @ g m a i l . c o m )
B . E n g ( H o n s ) , P. E n g , F I E M , J u r u t e r a G a s

Part

Circuit

Design

SYNOPSIS

Cable sizing is a fundamental skill set required of the design engineer.

Unfortunately the theory and empirical basis on which cable sizing rest on is not
well understood amongst practicing engineers. Such gaps in knowledge may have
implication in the design of wiring systems particularly on the safety of wiring
systems (particularly thermal safety).
This Presentation provides an introduction to basic concepts in sizing of cables in
electrical (LV) system based on the IEC standards. The presentation is based on
the handbook published and is in the following logical procession:
1.

Introduction

2.

Scope

3.

General Design Procedure (design road map)

4.

Earthing system

5.

Cable types & installation method

6.

Circuit configuration
26 January 2015

7.

Conductor sizing

THE SPONSOR WIRING HANDBOOK

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This handbook
is distributed
FREE courtesy
of the sponsor
23 r d August 2014

INTRODUCTION ROAD MAP TO IEC60364

Protection Device

Load Estimation

Cable
Selection
L.V. Wiring Design

Circuit
Configuration

Installation
Method

Earthing
Verification
Equipment Selection

26 January 2015

26 January 2015

VOLTAGE STANDARD

Malaysian Standard Voltages

It is a misconception that Malaysia Standard Voltage is at 415V/240V !

As of 1st January 2008, Malaysia Standard Voltage is declared at

400V/230V
Refer ST link for the official notification.

Rationalisation of voltage is to bring Malaysia in line with other

member countries of the IEC. Singapore and the UK has
already converted to 400V/230V from the old 415V/240V.
Other IEC member countries which have yet to convert are
Germany / China (380V/220V) and India (415V/240V).
Practitioners must therefore design power distribution system
to 400V/230V.
26 January 2015

VOLTAGE STANDARD

Malaysian Standard Voltages at 400V/230V +10%, -6%

Electrical power distribution system should be designed to 400V/230V !
Change all reference in specifications to 400V/230V.
Specify transformers at nominal 11kV/420V (not 11kV/433V).
Check cable sizing as 400V/230V incur about 4% higher current.

Major reasons for rationalising to 400V/230V

Standardisation among IEC countries. Multiple certification due to different
voltage levels is avoided or minimised.
Most motors and fluorescent light fittings works most efficiently within the
voltage band of 210V to 220V. Thus reducing to 220V will
Save energy
Prolong life-span of electrical equipment.
26 January 2015

10 VOLTAGE STANDARD

Version 3
Published
in 2013!
23 r d August 2014

26 January 2015

11 THE DESIGN WORK FLOW

26 January 2015

13 EARTHING SYSTEM
60364 - Part 1; 312 2 Letters definition:

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14 EARTHING SYSTEM

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15 EARTHING SYSTEM
Network / Operation Criteria
Service Criteria

System Chosen / Preferred

Competent Maintenance

Continuity of service critical

Available

IT System preferred

Continuity of service critical

Not consistently available

No satisfactory solution
IT system preferred as discriminitive
trippings are easier to implement and
damages less with respect to TN
system

Continuity of service NOT critical

Available

TN-S system preferred (rapidrepairs

and extension easily performed.

Continuity of service NOT critical

Not available

No satisfactory solution. IT system

preferred.

Fire hazard critical

Available

IT system and use of 5mA RCD or TT

system preferred.

Special feature, very long networks

Assumed available

TT preferred

Special feature, standby power supply

Assumed available

TT preferred

Special feature, load sensitive to high currents

(e.g. motors)

Assumed available

TT preferred;
IT can be acceptable

Special feature, low natural insulation (furnace)

OR very large HF filters (computers)

Assumed available

TN-S preferred

Special feature, control and monitoring systems

Assumed available

23 r d August 2014

IT for continuity of services; TT for

enhanced equipotential

16 EARTHING SYSTEM SIZING OF P.E. (TT)

60364-5-54, 312 :
For TT system, PE need for
exceed
25mm (copper)
35mm (aluminium)

As TT system effectively DO
NOT have PE cables within the
distribution system, this may
presumably mean the earth
electrode or frame earth system.

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17 EARTHING SYSTEM SIZING OF P.E. (TNS)

60364-5-54, 543 For TN-S system (method 1):
Cross sectional
areas of line
conductors
S
(mm)

If the protective conductor

is of the same material as
the line conductor

If the protective conductor is

not of the same material as
the line conductor

S < 16

K1/K2 x S

16 < S < 35

16 a

K1/K2 x 16

S > 35

Minimum cross sectional area of the corresponding

protective conductor (mm)

S/2

K1/K2 x S/2

Where
K1 is the value of k for the line conductor, selected from table A54.1 or from the
tables of IEC50364-4-43 according to the resistance of the conductor and
insulation.
K2 is the value of k for the conductor selected from tables A 54.2 to A54.6 as
applicable
a

for a PEN conductor the reduction of the cross section area is permitted
only in accordance with the rules for sizing of the neutral conductor (see IEC
23 r d August
60364-5-52).

2014

18 EARTHING SYSTEM SIZING OF P.E. (TNS)

60364-5-54, 543 For TN-S system where the protective device afford
disconnecting time NOT exceeding 5 seconds, the following formula may apply:

S = PE size (mm); I = prospective fault current rms; t = operating time of

protection device; k = factor based on conductor material and insulation.

19 EARTHING SYSTEM SIZING OF P.E. (TNS)

4x16mm PVC +
1x16mm PVC (PE)

Case :

SCI=10kA

Calculating
I t for PE:

70C PVC cables

30A
CB

k= 115

30A MCB class C, trip time

SC I=

3 kA

5 kA

6 kA

10 kA

15 kA

25 kA

t=

0.1 s

0.01 s

0.01 s

0.01 s

0.01 s

0.01 s

8.25

4.3

5.2

8.7

13.0

21.7

0.01 s

0.01 s

0.01 s

0.01 s

0.01 s

0.01 s

2.61

4.3

5.2

8.7

13.0

21.7

S min size of PE cable (mm)

32A gG Fuse, trip time
S min size of PE cable (mm)

t=

From the above, we note that for up 15kA rating table 54.3 sizing for PE cable
will be acceptable in terms of energy-let-through for both gG fuses and MCB
class C and B types.
26 January 2015

26 January 2015

21 CABLE TYPES
Cable types and installation methods have implication for cable sizing and
Ampere capacity.
IEC60364-5-52 : Cable Selection can be summarised:

26 January 2015

22 CABLE TYPES ASSESSING CONDITIONS

Part 5-51 defines environmental classes for use in defining
installation and equipment selection criteria:

A A 2
Number severity index
2nd alphabet
Specific conditions

A = Environment
B = Utilisation
C = Building

Specific conditions of environment usage etc are coded.

Later prescription in standards specify technical
conditions concerning conditions code.

26 January 2015

23 CABLE TYPES ASSESSING CONDITIONS

External influences

Selection considerations

AA4, and AA5

Normal cable insulation PVC, or XLPE

AD5 to AD7

Ambient temp.
-5C to +40C
Presence of water

AE5 and AE6

Dusty atmosphere

AG3

Mechanical stress

AH2

Vibrations

AM1

Harmonics

Cable jointing glands to be IPX5 and better,

extruded inner sheath for cables for AD7
(submerged)
Cable jointing glands to be IP6X, bare conductor
on insulator not recommended.
Underground cables, mechanical protection of
cables, sheathing of cables, armouring of cables,
cable in ducts
Connections to motor; termination lugs, cable
slack to allow for vibration
Mitigations for harmonics; Annex D in 60364-5-52
26 January 2015

24 CABLE TYPES ASSESSING CONDITIONS

External influences

Selection considerations

AN3

Solar radiation

AP3 and AP4

Seismic effect

BD2 and BD4

Emergency
evacuation;
difficult exit
Fire risk

Cable sheath or insulation which are immune

against UV radiation (PVC sheath or insulation not
permitted).
Cable tray preferred over conduit, slack in cable
run etc.
Low smoke (LSZH) cables

BE2
CA2
CA2 and BE2

Presence of
combustibles
Combustibles and
explosion risk

Fire rated cables for essential services; LSZH

cables
Fire rated cables for essential services; LSZH
cables
Design to IECEx standard IEC 60079 series.

26 January 2015

25 CABLES FOR FIRE & SMOKE CONDITIONS

Flame retardant cables do not promote or propagate the spread of fire.
Flame retardant cable installation is specified under conditions of
emergency evacuation (BD2 and BD4 external influences). These
conditions of emergency evacuation also apply in building spaces
designated as fire escape routes or emergency evacuation routes under
life safety standards for building design.
The degree of flame retardant required will depend on the designed
evacuation-time of the escape routes. The test for compliance to flame
retardant properties are defined in the IEC 60332 series:
IEC 60332-1 & 60332-2; flame propagation test on
single cable is the most basic flame retardant test
(whilst Part 1 specify 1kW flame for general insulated
cables, Part 2 specify diffuse flame for single
insulated small cables);
IEC 60332-3; specify more stringent flame
propagation test on bunched cables.

26 January 2015

26 CABLES FOR FIRE & SMOKE CONDITIONS

Low Smoke, Zero Halogen (LSZH) cables reduces smoke with zero
halogen emission. Classes of cables listed as Low Smoke Flame
Retardant (LSFR) or Low Smoke Zero Halogen (LSZH) are defined by the
following test standards:
The test for Low Smoke is the smoke density test of IEC 61034;
The test for halogen emission is specified in IEC 60754-1; and
The test for degree of acidity of is specified in IEC 60754-2.

26 January 2015

27 CABLES FOR FIRE & SMOKE CONDITIONS

Fire Resistant (FR) cables can maintain circuit integrity even in the
presence of a fire. The test for fire resistive behaviour is specified in IEC
60331 fire integrity tests. FR cables are mandatory where essential
services (e.g. fire fighting services, fire lifts etc) require circuit survivability
even during a fire emergency).
1. LSFR, LSZH sheath
2. Binder tape
3. Filler, non-hygroscopic

4. Insulation, XLPE-FR
5. Mica tape (fire resistant barrier)
6. Conductor, solid or stranded.

26 January 2015

28 CABLES FOR FIRE & SMOKE CONDITIONS

26 January 2015

29 CABLES FOR FIRE & SMOKE CONDITIONS

26 January 2015

30 CABLES TYPES

26 January 2015

31 CABLE TYPES COMMON DEFECTS

Conductors and cables

Bare
conductors

Insulated
conductors

Sheathed cables
(including armoured and
mineral insulated)
Multi core Single core

NA

Method of Installation

Without fixings

Clipped direct

Conduit systems

Cable trunking systems (including

skirting trunking, flush floor

trunking)
Cable ducting systems

Cable ladder, cable tray,

cable brackets
On insulators

NA
NA
Support wire

permitted
not permitted NA not applicable or not normally
used in practice
23 r d August 2014
Table 5A Cable installation method and cable types from IEC 60364-5-52

32 CABLE TYPES COMMON DEFECTS

Some Common Defects
1. PVC conduit system are
substandard and are NOT
certified to electrical grade.
2. PVC conduit and/or cables
laid in condition where
continuous sunlight occurs
(PVC will deteriorate in the
presence of UV light).
3. Conduit embedded in concrete are of the wrong grade (conduit not properly graded
will crack when laid in concrete).

4. No proper junction boxes and/or terminal boxes.

5. Trunking and/or conduit overloaded.
6. Splicing/jointing of cables without proper terminal box.

No proper evaluation on firerating of cables in complying

with fire properties.

PVC products should NOT be

installed exposed to sunlight.

26 January 2015

34 CIRCUIT CONFIGURATION EARTHING

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35 CIRCUIT CONFIGURATION

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36 CIRCUIT CONFIGURATION

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37 CIRCUIT CONFIGURATION

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38 CIRCUIT CONFIGURATION

26 January 2015

39 CIRCUIT CONFIGURATION

Fixed Installations

Types of wiring
system

Circuit use

Cables and
insulated
conductors

Power & lighting circuits

Bare
conductors

Power circuits

Signalling & control circuits

Signalling & control circuits

For specific appliance

Material
Copper

Conductor
Cross sectional area
1.5mm

Aluminium

10mm (note 1)

Copper

1.5mm (note 2)

Copper

10mm

Aluminium
Copper

Connections
with
For any other applications
flexible
conductors
Copper
and cables
Extra low voltage circuits for special
applications
Table 6 Minimum cross sectional area of conductors (from table 52-2)

16mm
4mm
Specified in relevant
IEC
0.75mm

0.75mm

26 January 2015

40 CIRCUIT CONFIGURATION

26 January 2015

WIRING DESIGN WORKSHOP

C A B L E

S I Z I N G

F U N D A M E N TA L S

Cable Sizing For Safe Power

System Based on IEC Standards
I r . H . P. L o o i ( m e k t r i c o n @ g m a i l . c o m )
B . E n g ( H o n s ) , P. E n g , F I E M , J u r u t e r a G a s

Part

Circuit

Design

Intermission-Continue to Part 2,,,