ELECTRICAL INSTALLATION

ECEg4241

Lecture 3 part 2
Department of Electrical & Computer
Engineering
Debre Berhan University

By Degarege.A

1
 Wire and cable size selection for known constant loads

The size should neither be so small so as to have a large internal voltage drop and large heat nor
be too large so as to cost too much.

The main factors to be considered When selecting size of a conductor or cable

Voltage drop: caused by the resistance of the cable of the required length must not exceed a
limit given as a standard.

The maximum current: liable to flow in the circuit without undue heating.

Operating temperature of the cable

Grouping, their spacing distance, underground or in open air as well as insulation factors
 Con…..
Individual conductor wires and each conductor of a cable are manufactured in the
following international standard sizes in which the wires are circular and may be solid or
stranded.
Standard
nominal
cross
section 0.5 0.75 1 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300 400 500 630
of bare
wire
(mm2)
Purpose Data Electric power cables
3
cable etc
 Cable size selection accounting voltage drop calculation
Cable/conductor size selection for dc and single phase wires (Using pure analytical
method (without table reference)

Let consider the two wire circuit (single phase). The voltage drop on the pair of cable is

V  V1 – V2  2IR
where R = L/σA ; R in Ω, L in meters, A in mm2 and σ in m/Ω-mm2

For copper σ = 57 m/Ω-mm2 (i.e in unit of meter per ohm mm2 ) and for aluminum σ =
33 m/Ω-mm2
 Cont.d
 Thus cross sectional area of the wire can be related to the loading must satisfy

V  2IR  2IL /  A or A  mm 2   2IL  m  / V

 If ∆V is in percentage of the rated value [i.e (∆V/V)100% = C or ∆V = C V/100].

A  mm   200 xI [ A]xL[m] /  CV
2

 If power is given instead of current

A  mm   200 xP[W ]x L[m] /  CV

2 2

 In lighting designs voltage drop of up to 5% of rated value are allowed [EEPCO regulation 2.5%
max].
Example 1
A 1 kW electric appliance is to be supplied from a 220V from a single phase
source 200m away. Assuming an allowed 2.5% voltage drop, what cross
sectional area of copper wire must be used?

Solution:

A (mm2) ≥ 200 x 1000W x 200m/(57 x 2.5 x 2202 ) = 5.8 mm2

Since 2 x 5.8mm2 cable is not available in the standard, the next higher size,
i.e. 2 x 6 mm2 cable will be used.
 Example 2
Each conductor of a copper cable of length 200m has a cross sectional area of 10mm2. The cable supplies power to a 220V

single phase motor of 5 kW rating that works on full load at cos ϕ = 0.87 and efficiency of 87%. Determine; the sending side

voltage required, the power loss in the cable, the inductance voltage drop at 50Hz

Solution: Resistance of the conductor of the cable pair, R = L/σA, Rph = 200/ (57 x 10) = 0.35 Ω

The current in each conductor, I = P/ (ɳVLcos ϕL) = 5000/ (0.87 x 220 x 0.87) = 30 A

Vs = Vr + ∆VR = where ∆VR = 2IR cos ϕL = 2 x30 x 0.35 x 0.87 = 18.27 V and Vs = 220 + 18.27 = 238.27 V

Ploss = 2I2R = 2 x 302 x 0.35 = 630 W

 Inductance: X = 0.4 Ω/km for overhead lines and X = 0.1 Ω/km for cables

Thus using the above approximate value ; ∆Vx = 2 I X sin ϕL = 2 x 30 x (0.1Ω/km x 0.2 km) x 0.493 = 0.59 V

We see ∆Vx << ∆VR ; Reactive power in the cable would be Q = 2I2X = 2 x 302 x 0.1 H/km x 0.2km = 36 var
 Con…
∆V = 2RI cos ϕ, Since, R = L/σA, ∆V = 2 I L cos ϕ/(σA ),

A(mm2) = 2LI cos ϕ/(σ ∆V) and I = P/(ɳV cos ϕ);

A (mm2) =2Lcos ϕ [P/(ɳVcos ϕ)]/ (σ ∆V) = 2LP/( ɳσV∆V)

If ∆V is in percentage of the rated line voltage V, i.e. ∆V = C V/100

A(mm2) = 200 LI cos ϕ/( ɳσ C V) or A (mm2) = 200 LP/(ɳ σ C V2)

Lost power in %, PL%= (Pl /P) x 100 = [2RI2/ (V I cos ϕ)] x 100 =200 RI/ (V cos ϕ)

and with R = L/σA, PL%= 200 L I/( ɳσAVcos ϕ)

Or since I = P/ (V cos ϕ), PL%= 200 L [P/(V x cos ϕ) ]/ ( σ A V cos ϕ)

PL%= 200 LP/ ( ɳ2 σ A V2 cos2 ϕ)

 Example 3
At the end of a line of 50 m length, a single phase motor of 5kW, 220V, cos ϕ = 0.8 and

efficiency = 0.82 is connected. Voltage drop is 6.6V. Determine the cable size and percentage of lost
power in the cable.
Solution
A(mm2) = 2LP/( ɳσV∆V) = 2 x 50 x 5000/(0.82 x 56 x 220 x 6.6) = 7.4875 mm2,
choose 10 mm2
Or C = (6.6/220) x 100 = 3 %
A (mm2) = 200 LP/ (ɳσ C V2) = 200 x 50 x 5000/ (0.82x56x3x2202) = 7.4875mm2
PL%= 200 LP/( ɳ2σ A V2 cos2 ϕ) = 200 x 50 x 5000/(0.822 x 56 x 6 x 2202 x 0.82) =7.125 %
Or PL%= 200 L I/ (ɳσAVcos ϕ) where I = P/ (ɳVcos ϕ) = 5000/(0.82 x 220 x 0.8) = 34.65A
PL%= 200 x 50 x 34.65/ (0.82 x 56 x 6 x 220 x 0.8) = 7.125%
 Cable size calculation with voltage drop in unbranched three phase wires
 General ac load (reactive + resistive)

 The triple wire power cable of length L is assumed to have only resistance R in each line but negligible
inductance.
Lost power on cable ∆P = PS - Pr
∆P = 1.73 I x Vs cos ϕs - 1.73 I x Vr cos ϕ
∆P = 1.73 I (Vs cos ϕs - Vr cos ϕ) = 3 I2R
∆V = 1.73 I R cos ϕ and with R = L/σA, ∆V = 1.73I L cos ϕ/(σA)
A(mm2) = 1.73 L I cos ϕ/(σ ∆V)
Since I (A) = P/( ɳ1.73 Vcos ϕ)
A (mm2) = 1.73 L [P/( 1.73 Vcos ϕ) ] cos ϕ/(σ ∆V)
A (mm2) = L P /( ɳ σ ∆V V)

A (mm2) = 173 L I cos ϕ/ (σ C V) or A (mm2) = 100 L P / (ɳσ C V2)

Lost power analysis
Example 4
Sixty incandescent lamps of 100W each are connected to a three phase mains
of 220/380V. Length of the line is 50m. Admissible voltage drop is 5V.
Determine the size of the conductor per phase.

Solution: Here cos ϕ = 1; ɳ= 1, P = 60 x 100 = 6000W; V = 380V;

L = 50m, ∆V = 5V

A = L P/(σ ∆V V) = 50 x 6000/(56 x 5 x 380) = 2.8 mm2

=> choose 4 mm2.

 Example 5
A total power of 11kW is to be transmitted over a distance of 90m in a three
phase mains of 220V. The power factor cos𝞥 = 0.8
and voltage drop C = 5%. Determine the size of the conductor and the lost
power in %.
Solution: Here = 1
A (mm2) = 100 L P / (ɳ σ C V2)
= 100 x 90 x 11,000/ (1 x 56 x 5 x 2202) = 7.3 mm2
=> choose 10 mm2
PL% = 173 x I x L/ (σ x A x V x cos ϕ)
I = P/ (1.73 x V x cos ϕ) = 11,000/ (1.73 x 220 x 0.8) = 36 A
Thus, PL% = 173 x 36 x 90 / (56 x 10 x 220 x 0.8) = 5.6%
 Cable size determination: Table reference method
A simpler approach in electrical installation design is to use pre calculated values of voltage drops of the
type prepared by the Institute of Electrical Engineers (IEE).

14
 Maximum continuous loading of insulated conductors and coordination of
protective devices (Copper conductors at 25 Deg Celsius ambient temperature)

15
Example 6
A tannery requires three raw waste transfer pumps of rating 10 HP

each driven by a three phase star connected induction motor. The

motors are supplied from a switch board situated 50m away.

Determine the size of cable and the automatic circuit breaker

rating required. Assume a 2.5% voltage drop may be tolerated

where supply to the motors is 380V line. For each motor cos ϕ is

0.88 and efficiency = 0.88.

Solution:
For each motor, In = 10 x746/1.73x380x0.88x0.88 = 14.64 A

Type of cable selected = 4 core PVC sheathed and the allowable voltage drop = (2.5/100) x 380 = 9.5V

From the above table we calculate for 1mm2: max. continuous current rating 16A; ∆V/A/m = 36 mV

∆V = 14.64 x 50 x 36 x 10-3 = 26.35V > 9.5V (not good enough)

for 1.5 mm2: rating 20A; ∆V/A/m = 24 mV

∆V = 14.64 x 50 x 24 x 10-3 = 17.5 V > 9.5V (not good enough)

for 2.5 mm2: rating 27A; ∆V/A/m = 14 mV

∆V = 14.64 x 50 x 14 x 10-3 = 10.2 V > 9.5V (still not good enough)

for 4 mm2: rating 35A; ∆V/A/m = 9 mV: ∆V = 14.64 x 50 x 9 x 10-3 = 6.6 V < 9.5V

Thus we take 4 x 4 mm2

Example 7 (previously solved)
Each conductor of a copper cable of length 200m has a cross sectional area of 10mm2. The cable supplies
power to a 220V, single phase motor of 5kW rating that works on full load at cos ϕ = 0.87 and efficiency of
87%. Determine; a) the supply voltage required b) the power loss in the cable c)the inductance voltage
drop at 50Hz.

Solution

It has been found that I = 30A; ∆VR = 2IR cos ϕL = 18.27 V

Using table 2, consider two cable single core 10 mm2.

We see ∆V/A/m = 4.2 mV

∆V = 30A X 200m X 4.2 x 10-3 V/A/m = 25.2 V > 18.27

According to EEPCOs regulation, for an enclosed cable, ∆V/A/m = 5V/50m/40A = 2.85 mV/A/m

∆V = 30 x 200 x 2.85 x 10-3 = 16.8V < 18.27V

Example 8:
A 1 kW electric appliance is to be supplied from a 220V from a single
phase source 200m away. Assume an allowed 2.5% voltage drop and max
operating temperature of a rubber insulated copper conductor cable to
be 45 OC. Determine the appropriate cross sectional area of copper wire
to be used to satisfy the constraints.
Solution
I = P/V = 1000/220 = 4.5 A. And for this we read from table a size
of 1.0 mm2 (which has a max. permissible continuous loading
capacity of 12A at 250C) is quite sufficient.

At a temperature of 45 OC, the current carrying capacity of the

conductor reduces to 65%, i.e. it would carry 0.65 x 12 A = 7.8 A.
This is still sufficient.
 Con….
From voltage drop consideration, the cross section should be at 25OC,
A (mm2)≥200 x P x L / σCV2 then A = 200 x 1000 x 200/(57 x 2.5 x 2202 ) = 5.8
mm2
Since σ (T) = 1/ р(T) =1/ р25(1 + α∆T) => σ (T) = σ 25/(1 + α∆T) = 57/[1 + 0.0039
(Tf – 25)]
Thus at T = 45OC, σ (T) = 57/[1 + 0.0039 (45 – 25)] = 52.87 S m/mm2
And A (45OC) = 200 x 1000 x 200/(52.87 x 2.5 x 2202 ) = 6.25 mm2
Thus choice of cable = [(A >= 1.0 mm2)∩(A >= 6.25 mm2)] => A = 6.25 mm2 we
thus choose the next higher size, i.e. A = 10 mm2
 Cable size selection accounting number of conductors
If circuits were grouped with other circuits or if multicore cables were bunched with other
multicores in an enclosure, the heat dissipation properties of the circuits or cables would be
reduced.

 The more cables there are in the group the dissipation properties of the cable are reduced.

 If cables were loaded to their ungrouped level, when they are grouped they would overheat.

 The number of grouped circuits must therefore be taken into account.

 For instance, for two enclosed multicore cables bunched and clipped direct to a non-metallic surface, Cg =
0.80. This means that for two circuits, only 80 percent of the single circuit current is allowed.
 Con…
Table for correction factors Cg to account for grouping
No. of multicore groups, or multiple circuit 1 2 3 4
group
Grouping correction factor, Cg 1 0.8 0.7 0.65

If the current rating of one of the cables in non-grouped condition is Iz,

then the new current capacity when grouped with other cables will reduce

to I/z = Cg x Iz
 Con…..
If, ambient temperature change is encountered for the bunched cables, the combined
correction factor of grouping and temperature will be C = Cg x Ca.

This means that the current capacities of each of the cables is reduced by a factor of C,
i.e. I/z = C x Iz.

If the cable is run in heat-insulating material, its ability to dissipate heat will be impaired.

A heat insulation correction factor Ci is applied to the length of the cable Combined
effects will result a combined correction factor C = Cg x Ca x Ci and I/z = C x Iz.
Cable size selection accounting protective device & correction factors

The protective device current rating In should be greater than the design
current Ib of the circuit or appliance. That is, In ≥ Ib and its value is
selected from standard tables.

For the protective device to protect the cable against overload, the
minimum cable rating, Iz=In or Iz ≥In.

Under normal condition (25OC, un-grouped, and with no heat insulation),

the tabulated rated value of the cable Iz = It ≥ In.
 Con…
When one or all correction factors are to be accounted, use them as
divisor/s to determine the corrected rating of the cable as

I/z = Min. It = In/Cg×Ca×Ci or I/z = It ≥ In/Cg×Ca×Ci

When a rewireable fuse is to be used, a factor of 0.725 is used in addition.

The formula is now amended to I/z = Min. It = In/Cg×Ca×Ci x 0.725

or I/z = It ≥ In/{Cg×Ca×Ci x 0.725}

If any of the factors are not applicable, ignore them or replace with equal to 1
26
Example 9
Single-phase 240V, 36A loads are to be supplied by means of 70°C
thermoplastic PVC twin and earth cables having copper conductors, 25m
in length, in an area having an ambient temperature of 35°C (Ca= 0.94).
The cables are touching and single-layer clipped to a non-metallic surface
(for 3 circuits Cg=0.79). The overcurrent device at the origin of the
installation is a type-B MCB to BS EN 60898. Calculate the minimum
permissible cable size.
 Solution
Design current Ib =36A. Nominal rating of the device (from table)

In=40A ( Ib), Cg=0.79, Ca=0.94.

 Thus, tabulated rating of cable Iz = It ≥In/Cg x Ca = 40/0.79 x 0.94

=53.86A

Consulting manufacturer’s appropriate table, It = 65A.

 Therefore, the minimum size with respect to current carrying capacity

is 10mm2.
 Con…..
A(sq.mm) Multicore cable, Max. Permissible
Continuous loading (A)
1 16
1.5 20
2.5 27
4.0 36
6.0 47
10 65
16.0 85

29
 Con…
If the volt drop does not exceed 4% of the nominal voltage of the mains

∆V = 240 x 0.04 = 9.6V

We now need to check that the voltage drop in the 10mm2 cable is within these limits.

Table for the cable gives voltage drop in millivolts per ampere per meter of 4.2.

To calculate the voltage drop, multiply mV/Amp/m x Ib x Meters/1000. Thus

∆V = 4.2 x 36 x 25/1000 = 3.078V < 9.6V.

We see therefore, the minimum permissible size is 10mm2.

 Con….
If the circuit was protected by a rewireable fuse to BS 3036, the design of the circuit
would be slightly different.

Design current Ib=36A. Nominal rating of the device In=40A (a rewireable fuse to BS
3036); Cg=0.79, Ca=0.97.

Thus Iz = It ≥In/Cg x Ca x 0.725 = 40/0.555=72A

Consulting manufacturer’s appropriate table, It = 85A.

 Minimum size with respect to current carrying capacity is 16mm2.

Voltage drop ∆V = mV/Amp/m x Ib x Meters/1000 = 2.6 x 36 x 25/1000 = 2.34V <

9.6V. Therefore, the minimum permissible size is 16mm2.
Summarized Cable Size Selection Procedure for Constant Load or Final circuits

Determine design current, Ib , based on continuous load of cable.

PL
 Single phase I b 
PL
Three phase Ib 
V cos  3 *VL cos 
Select cable type for desired application (for over head, underground, indoor, outdoor,

wet, dry etc)

Apply correction factors

Check for the allowable voltage drop

Typical cable and protection device selection for common appliances refer to [EBCS]

Socket outlets
 Up to 8 sockets outlets can be fed by a feeder of cable size not less than 2.5mm2
protected by fuse of 15A, if the socket outlets are to serve less than 30m2 area, but not
kitchen.

If the area is above 30 m2 and cable is 2.5mm2, the number of socket outlets connected
to a feeder has to be 4 or less with 15A protection fuse.

But, if the cable size is increased to 4 mm2 with a protection fuse of 25A, the number
of socket outlets can be up to 8 for area more than 30m2.
 Con….
Maximum number of socket outlets on one feeder when the
load is not known exactly is limited to 12.

If the socket outlet is for a particular portable appliance of

rating more than 1500W, it has to be fed through a separately
controlled and protected dedicated feeder.

The feeder cable size and protection device should be

determined based on the appliances continuous current rating.
Lighting Points

Lighting points can be connected in parallel to the same feeder if the

total current in the feeder is less than 15A and protected by a 16A fuse.

If the power of lighting point is not known exactly, a 100W can be
assumed per lamp holder for the feeder total current calculation.

Heating and general electric appliances

Any appliance with power rating of more than 1500W has to be fed by a
dedicated cable with its own control and protection
Electric Motor Installation
Electric motors can be of continuous duty, intermittent duty or short time duty.
Six steps can be used for the installation of electrical motors
Determining the motor full load current.

Determine the size of the motor branch circuit conductor

Determine the fuse size (dual element) to be used as motor branch-circuit short circuit and
ground fault protection.

Determine the rating requirement for the motor disconnecting switch.

Determine the motor and branch circuit overload protection requirement

Determine the requirement for the motor control circuit over current protection
Example 11
It is desired to design and installs a squirrel cage induction electric motor fed from a
380V bus-bar. The electric motor nameplate values are Pn= 2.2 kW, nn=2850 rpm,
Vn=380V, pf=0.8, ɳ=0.8. The motor is for continuous duty operation.
Solution:
Step 1: The full load current of the motor can be obtained from the following equation. If
the efficiency is to be considered the motor current would be slightly higher.

Pn 2200
Ib    5.22 A
3VL * * pf 1.73*380*0.8*0.8
Step 2: Assuming no correction factors for ambient and group, etc. the minimum ampacity of
conductor to be used according to standards is 125% of the motor full load.

Iz = 5.22 x 1.25 = 6.525A

 The corresponding size for particular cable to be used checked from table.

 Table I: Single core PVC insulated copper conductor with sheath, current carrying capacity
and voltage drop.

Example: from the following table it is 1 mm2 can be used.

 Is to be greater than the full load current 16 A can be chosen.

Diversity [Demand] factor:- is the ratio of the maximum demand of a load to the total
connected load . This factor is also called factor of power utilization.
Therefore demand factor have been established, based on many tests and past experiences.
As every single load or group of loads in a circuit are not operating simultaneously, and
normally working under partial load, the power demand factor is always less than 1.0.
Type of load DF estimate
Lighting Circuits 0.7-0.9
Heating loads
Water Heaters 0.2-0.3
Ovens/stoves 0.2
Electric Iron 0.3
Motor Loads 0.7-0.9
Office equipment 0.3-0.5
General purpose SOs 0.2-0.5
Circuit Diagrams
No. of light points (lamps) per lighting circuit = 15
No. of sockets per circuit = 4
No. of space heater = 1
No. of water heater = 1
Determine
a) the estimate of maximum power demand, Pmax
b) the rating of the main switch
c) the size of the feeder cable

41
 Solution
Circuit Power without DF Power with DF
Lighting 4 x 220 x 10 = 8800W 0.7 x 8800 = 6160W
Socket outlet 3 x 220 x 16 = 10560W 0.2 x 10560 = 2112W
Water heater 220 x 16 = 3520W 0.2 x 3520 = 704W
Space heater 220 x 25 = 5500W 0.2 x 5500 = 1100W
28380 Pmax 10076W
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Assignment

44
Thank you