Cabl e Si zi ng For Safe Power

System Based on IEC Standards

I r . H. P. Looi ( me k t r i c o n @g ma i l . c o m)
B. Eng ( Hons ) , FI EM, J ur ut er a Gas
Cable Sizing Fundamentals and
El e c t r i c a l LV St a n d a r d
Ar mada Hot el , Pet al i ng J ay a
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P a r t 1 C i r c u i t D e s i g n
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:
2 SYNOPSIS
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1. Introduction
2. Scope
3. General Design Procedure (design road map)
4. Earthing system
5. Cable types & installation method
6. Circuit configuration
7. Conductor sizing
3 THE SPONSOR WIRING HANDBOOK
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The International Copper Association Ltd. (ICA) is a non-profit
organization promoting the use of copper worldwide . ICA increases
awareness and usage of copper by communicating its unique attributes as a
sustainable element an essential to life, science and technology, and a higher
standard of living. ICA Southeast Asia established by ICA in 1992 acts as a
strategic and networking base for regional copper and associated industries
associations.

This handbook
is distributed
FREE courtesy
of the sponsor
5 INTRODUCTION ROAD MAP TO IEC60364
Load Estimation
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L.V. Wiring Design
Circuit
Configuration
Installation
Method
Cable
Selection
Protection Device
Earthing
Equipment Selection
Verification
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8 VOLTAGE STANDARD
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Malaysian Standard Voltages
It is a misconception that Malaysia Standard Voltage is at 415V/240V !
As of 1
st
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.
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Malaysian Standard Voltages at 400V/230V +10%, -6%
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.
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.
9 VOLTAGE STANDARD
10 VOLTAGE STANDARD
Version 3
Published
in 2013!
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11 THE DESIGN WORK FLOW
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13 EARTHING SYSTEM
60364 - Part 1; 312 2 Letters definition:
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14 EARTHING SYSTEM
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Network / Operation Criteria System Chosen / Preferred
Service Criteria 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 IT for continuity of services; TT for
enhanced equipotential
15 EARTHING SYSTEM
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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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Cross sectional
areas of line
conductors
S
(mm)
Minimum cross sectional area of the corresponding
protective conductor (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 S K
1
/K
2
x S
16 < S < 35 16
a
K
1
/K
2
x 16
S > 35 S/2
a
K
1
/K
2
x S/2
Where
K
1
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.
K
2
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
60364-5-52).
17 EARTHING SYSTEM SIZING OF P.E. (TNS)
60364-5-54, 543 For TN-S system (method 1):
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18 EARTHING SYSTEM SIZING OF P.E. (TNS)
S = PE size (mm); I = prospective fault current rms; t = operating time of
protection device; k = factor based on conductor material and insulation.
60364-5-54, 543 For TN-S system where the protective device afford
disconnecting time NOT exceeding 5 seconds, the following formula may apply:
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19 EARTHING SYSTEM SIZING OF P.E. (TNS)
Case :
Cal cul at i ng
I t f or PE:
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.
4x16mm PVC +
1x16mm PVC (PE)
30A
CB
SCI=10kA
70C PVC cables k= 115 SC I= 3 kA 5 kA 6 kA 10 kA 15 kA 25 kA
30A MCB class C, trip time t= 0.1 s 0.01 s 0.01 s 0.01 s 0.01 s 0.01 s
S min size of PE cable (mm) 8.25 4.3 5.2 8.7 13.0 21.7
32A gG Fuse, trip time t= 0.01 s 0.01 s 0.01 s 0.01 s 0.01 s 0.01 s
S min size of PE cable (mm) 2.61 4.3 5.2 8.7 13.0 21.7
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21 CABLE TYPES
Cable types and installation methods have implication for cable sizing and
Ampere capacity.
IEC60364-5-52 : Cable Selection can be summarised:
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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
2
nd
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.
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23 CABLE TYPES ASSESSING CONDITIONS
External influences Selection considerations
AA4, and AA5 Ambient temp.
-5C to +40C
Normal cable insulation PVC, or XLPE
AD5 to AD7 Presence of water Cable jointing glands to be IPX5 and better,
extruded inner sheath for cables for AD7
(submerged)
AE5 and AE6 Dusty atmosphere Cable jointing glands to be IP6X, bare conductor
on insulator not recommended.
AG3 Mechanical stress Underground cables, mechanical protection of
cables, sheathing of cables, armouring of cables,
cable in ducts
AH2 Vibrations Connections to motor; termination lugs, cable
slack to allow for vibration
AM1 Harmonics Mitigations for harmonics; Annex D in 60364-5-52
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24 CABLE TYPES ASSESSING CONDITIONS
External influences Selection considerations
AN3 Solar radiation Cable sheath or insulation which are immune
against UV radiation (PVC sheath or insulation not
permitted).
AP3 and AP4 Seismic effect Cable tray preferred over conduit, slack in cable
run etc.
BD2 and BD4 Emergency
evacuation;
difficult exit
Low smoke (LSZH) cables
BE2 Fire risk Fire rated cables for essential services; LSZH
cables
CA2 Presence of
combustibles
Fire rated cables for essential services; LSZH
cables
CA2 and BE2 Combustibles and
explosion risk
Design to IECEx standard IEC 60079 series.
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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.
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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.
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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.
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28 CABLES FOR FIRE & SMOKE CONDITIONS
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29 CABLES FOR FIRE & SMOKE CONDITIONS
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30 CABLE TYPES
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31 CABLE TYPES COMMON DEFECTS
Conductors and cables Bare
conductors
Insulated
conductors
Sheathed cables
(including armoured and
mineral insulated)
Multi core Single core
M
e
t
h
o
d

o
f

I
n
s
t
a
l
l
a
t
i
o
n

Without fixings NA
Clipped direct
Conduit systems
Cable trunking systems (including
skirting trunking, flush floor
trunking)

1

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
Table 5A Cable installation method and cable types from IEC 60364-5-52
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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.

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).
PVC products should NOT be
installed exposed to sunlight.
No proper evaluation on fire-
rating of cables in complying
with fire properties.
32 CABLE TYPES COMMON DEFECTS
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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
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39 CIRCUIT CONFIGURATION
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40 CIRCUIT CONFIGURATION
Cable Sizing For Safe Power System Based
o n I E C S t a n d a r d s
I r . H. P. Looi ( me k t r i c o n @g ma i l . c o m)
B. Eng ( Hons ) , FI EM, J ur ut er a Gas
Cable Sizing Fundamentals and
El e c t r i c a l LV St a n d a r d
Ar mada Hot el , Pet al i ng J ay a
23
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Augus t 2014
P a r t 1 C i r c u i t D e s i g n
Intermission-Continue to Part 2,,,