CABLE SIZING

CALCULATION
1 ) REFERENCE STANDARD :

MV CABLE SIZING :

IEC 60502-1

IEC 60502-2

IEC 60332

IEC 60287-3-1

IEC 60865-1-Part. 1

IEC 60949

LV CABLE SIZING :

IEC 60287

IEC 60332- Part 1

IEC 60364- Part 4-41

IEC 60364- Part 5-52

2 ) BASIS OF CALCULATION :

2.1.2. LV Cables

Type of cables:
Core Stranded copper, class 2
Shape Round
Rated voltage [Uo/U (Um)] 0.6 / 1 kV
Maximum permissible core temperature:
Normal conditions (permanently energized) 90°C
Fault current conditions 250°C
Insulation XPLE
External sheath PVC (IEC 60332)
Armoured No
Standard IEC 60502-1 / IEC 60364-5-52

2.2) Site Condition :

2.2.1 Design Ambient Temperature : 45 deg. C

2.2.2 Design Ground Temperature : 25 deg. C

2.6) De-rating factor for different laying methods : As per Cable manufacturer data sheet.

2.7) Current carrying capacities, AC Resistance at 90 deg. C and Reactance values : As per Cable
manufacturer data sheet.

2.8) Allowable Voltage drop in Cables :

2.8.1 Voltage drop during normal (Steady state condition) shall be restricted to 4%

2.8.2 Voltage drop during starting (Starting condition) shall be restricted to 15%
3) FORMULAS :

3.2) LV Cable Sizing :

3.2.1 Thermal ampacity of conductor verification :

Ic = Ic(max) x D x no. of runs

Ic = Thermal ampacity of conductor

Ic(max) = Maximum rating of conductor

D = De-rating factor

Ic > Full Load current of circuit

3.2.2 Steady State Voltage drop :

Vss = Iflc x Z / Vnom x 100%

Vss = Steady State Voltage drop

Iflc = Full Load current of circuit

Z = Impedance

Vnom = Nominal voltage

Steady state voltage drop ≤ 4%

3.2.3 Starting Voltage drop :

Vst = Ist x Zst / Vnom x 100%

Vst = Starting Voltage drop

Ist = Starting current of circuit

Zst = Starting Impedance

Vnom = Nominal voltage

Starting voltage drop ≤ 15%

4) ANNEXURES :

4.1 Sample Calculation Sheet

4.2 Cable vendor data sheets shall be enclosed during detail engineering.

4.3 Tabular List of all cable sizing sheet shall be enclosed during detail engineering.
4.1) Sample Cable Sizing Calculation

General Specification
1. Maximum voltage drop

Steady voltage for 415V system 4%

During Starting for 415V system 15%

2. Interupting Capacity

400V system 50 kA for 1.0 sec

3. Derating factor for cable As per IEC Standard & Manufacturer's data

Formula

1 Motor Full Load Current : I (FLC)

I (FLC) = P / (√3 * V * cos (PF) * e )
where :
I (FLC) = Full Load Current
(Ampere)
P = Motor Capacity (Watt)
V = Supply Voltage (Volt)
cos (PF) = Power Factor
e = motor efficiency (%) IE2 class efficiency as per IEC
2 Motor Current during starting : I (ST)
I (ST) = 6 * I (FLC)
where :
I (ST) = Motor Current during
starting (Ampere)
I (FLC) = Full Load Current
(Ampere)
3 Themal Ampacity of conductor : Ic
Ic = Ic(max) * D * no. runs
where :
Ic = maximum ampacity of
conductor
Ic(max) = maximum rating of conductor (as per IEC Standard & Manufacturer's
data)
D = derating factor (as per IEC Standard & Manufacturer's
data)
4 Cable Impedance (Z)
 Z = √ (R^2 cos^2ø + X^2 sin^2ø)
where :
Z = Impedance (ohm)
R = Cable resistance (ohm)
X = Cable reactance (ohm)
5 Cable Impedance at Starting (Zst)
Zst = √ (R^2 cos^2øst + X^2 sin^2øst)
where :
Zst = Impedance at Starting (ohm)
R = Cable resistance (ohm)
X = Cable reactance (ohm)
6 Nominal Voltage V (Nom)
V (Nom) = V / √ 3
where :
V (Nom) = Nominal Voltage
V = Supply Voltage (Volt)
7 Steady State Voltage Drop (Vss)
Vss = ( I (FLC) * Z ) / V (Nom) ) * 100%
where :
Vss = Steady State Voltage Drop
(%)
I (FLC) = Full Load Current
(Ampere)
Z = Impedance (ohm)
V (Nom) = Nominal Voltage
8 Starting Voltage drop (Vst)
Vst = ( I (st) * Zst ) / V (Nom) ) * 100%
where :
Vst = Starting Voltage Drop (%)
I (st) = Starting Current (Ampere)
Zst = Impedance at starting (ohm)
V (Nom) = Nominal Voltage
Typical 415 v Drive cable Selection

Drive A

Motor Specificaton
Motor Name Conveyor drive A
Base voltage (V) 400 V
Motor Capacity (P) 75 KW
Frequency 50 Hz
Type of motor Squirrel Cage Type
Motor Starting Current (I (ST)) 6 times FLC
Motor PF 0.85
Efficiency (IE2 class as per IEC) 0.85
Motor Starting PF (assumed) 0.40 (squirrel cage motor)

Cable specification
Selected Cable Cu,3c x 70 sqmm (armoured)
Current rating for selected cable (ground) 209 A
Max length of motor cable (estimated) 126 m
Resistance of cable (ohm/km) 0.268
ohm/km
Reactance of cable (ohm/km) 0.075
ohm/km
Short Circuit withstand 8.05 kA / 1 second
Derating factor 0.90
Number of runs 1.00

Calculation
Calculation for Ampacity of conductor
1
Full Load Current (I (FLC)) 149.8 A
Thermal Ampacity selected cable 188 A
Thermal Ampacity selected cable > Full Load Current (Condition Satisfy)

Calculation for Voltage Drop (steady)

2
Full Load Current (I (FLC)) 149.8 A
Nominal Voltage (V (Nom)) 230.9 V
ohm
Total cable resistance (R) 0.0338 126 m
for
ohm
Total cable rectance (X) 0.0094 126 m
for
 Cos (PF) 0.850
Sin (PF) 0.527
ohm
Total cable Impedance (Z) 0.029 126 m
for
Steady state voltage drop 1.89%
Voltage Drop < 4% (Condition Satisfy)

Calculation for Voltage Drop (starting)

3
Full Load Current during starting (I (ST)) 1,910.4 A
Nominal Voltage (V (Nom)) 230.9 V
ohm
Total cable resistance (R) 0.0338 126 m
for
ohm
Total cable rectance (X) 0.0094 126 m
for
Cos (PF) 0.40
Sin (PF) 0.92
ohm
Total cable Impedance (Z) 0.016 126 m
for
Starting voltage drop 13.26%
Voltage Drop < 15% (Condition Satisfy)

Selected cable : Cu,3c x 70 sqmm