Cable Sizing Calculation

Contents

 1Introduction
o 1.1Why do the calculation?
o 1.2When to do the calculation?
 2General Methodology
o 2.1Step 1: Data Gathering
 2.1.1Load Details
 2.1.2Cable Construction
 2.1.3Installation Conditions
o 2.2Step 2: Cable Selection Based on Current Rating
 2.2.1Base Current Ratings
 2.2.2Installed Current Ratings
 2.2.3Cable Selection and Coordination with Protective
Devices
 2.2.3.1Feeders
 2.2.3.2Motors
o 2.3Step 3: Voltage Drop
 2.3.1Cable Impedances
 2.3.2Calculating Voltage Drop
 2.3.3Maximum Permissible Voltage Drop
 2.3.4Calculating Maximum Cable Length due to Voltage
Drop
o 2.4Step 4: Short Circuit Temperature Rise
 2.4.1Minimum Cable Size Due to Short Circuit
Temperature Rise
 2.4.2Initial and Final Conductor Temperatures
 2.4.3Short Circuit Energy
o 2.5Step 5: Earth Fault Loop Impedance
 2.5.1The Earth Fault Loop
 2.5.2Maximum Cable Length
 3Worked Example
o 3.1Step 1: Data Gathering
o 3.2Step 2: Cable Selection Based on Current Rating
o 3.3Step 3: Voltage Drop
o 3.4Step 4: Short Circuit Temperature Rise
o 3.5Step 5: Earth Fault Loop Impedance
 4Waterfall Charts
 5International Standards
o 5.1IEC
 o 5.2NEC
o 5.3BS
o 5.4AS/NZS
 6Computer Software
o 6.1Desktop
o 6.2Online
o 6.3Mobile
 7What next?

Introduction

This article examines the sizing of electrical cables (i.e. cross-sectional area) and its implementation
in various international standards. Cable sizing methods do differ across international standards
(e.g. IEC, NEC, BS, etc) and some standards emphasise certain things over others. However the
general principles underlying any cable sizing calculation do not change. In this article, a general
methodology for sizing cables is first presented and then the specific international standards are
introduced.
Why do the calculation?
The proper sizing of an electrical (load bearing) cable is important to ensure that the cable can:

 Operate continuously under full load without being

damaged
 Withstand the worst short circuits currents flowing
through the cable
 Provide the load with a suitable voltage (and avoid
excessive voltage drops)
 (optional) Ensure operation of protective devices
during an earth fault
When to do the calculation?
This calculation can be done individually for each power cable
that needs to be sized, or alternatively, it can be used to
produce cable sizing waterfall charts for groups of cables with
similar characteristics (e.g. cables installed on ladder feeding
induction motors).

General Methodology
All cable sizing methods more or less follow the same basic six
step process:
1) Gathering data about the cable, its installation
conditions, the load that it will carry, etc
2) Determine the minimum cable size based on continuous
current carrying capacity
3) Determine the minimum cable size based on voltage
drop considerations
4) Determine the minimum cable size based on short
circuit temperature rise
5) Determine the minimum cable size based on earth fault
loop impedance
6) Select the cable based on the highest of the sizes
calculated in step 2, 3, 4 and 5
Step 1: Data Gathering
The first step is to collate the relevant
information that is required to perform
the sizing calculation. Typically, you
will need to obtain the following data:
Load Details
The characteristics of the load that
the cable will supply, which includes:

 Load type: motor or feeder

 Three phase, single phase or DC
 System / source voltage
 Full load current (A) - or calculate this if the load is
defined in terms of power (kW)
 Full load power factor (pu)
 Locked rotor or load starting current (A)
 Starting power factor (pu)
 Distance / length of cable run from source to load - this
length should be as close as possible to the actual
route of the cable and include enough contingency for
vertical drops / rises and termination of the cable tails
Cable Construction
The basic characteristics of the
cable's physical construction,
which includes:

 Conductor material - normally copper or aluminium

 Conductor shape - e.g. circular or shaped
 Conductor type - e.g. stranded or solid
 Conductor surface coating - e.g. plain (no coating),
tinned, silver or nickel
 Insulation type - e.g. PVC, XLPE, EPR
 Number of cores - single core or multicore (e.g. 2C, 3C
or 4C)
Installation Conditions
 How the cable will be
installed, which includes:

 Above ground or underground

 Installation / arrangement - e.g. for underground
cables, is it directly buried or buried in conduit? for
above ground cables, is it installed on cable tray /
ladder, against a wall, in air, etc.
 Ambient or soil temperature of the installation site
 Cable bunching, i.e. the number of cables that are
bunched together
 Cable spacing, i.e. whether cables are installed
touching or spaced
 Soil thermal resistivity (for underground cables)
 Depth of laying (for underground cables)
 For single core three-phase cables, are the cables
installed in trefoil or laid flat?
Step 2: Cable
Selection Based on
Current Rating
Current flowing through a
cable generates heat
through the resistive
losses in the conductors,
dielectric losses through
the insulation and
resistive losses from
current flowing through
any cable screens /
shields and armouring.
The component parts that
make up the cable (e.g.
conductors, insulation,
bedding, sheath, armour,
etc) must be capable of
withstanding the
temperature rise and
heat emanating from the
cable. The current
carrying capacity of a
cable is the maximum
current that can flow
continuously through a
cable without damaging
the cable's insulation and
other components (e.g.
bedding, sheath, etc). It
is sometimes also
referred to as the
continuous current rating
or ampacity of a cable.
Cables with larger
conductor cross-sectional
areas (i.e. more copper
or aluminium) have lower
resistive losses and are
able to dissipate the heat
better than smaller
cables. Therefore a
16 [math]mm^{2}[/math] c
able will have a higher
current carrying capacity
than a 4 [math]mm^{2}
[/math] cable.
Base Current Ratings

Table 1. Example of
base current rating table
(Excerpt from IEC
60364-5-52)

International standards
and manufacturers of
cables will quote base
current ratings of different
types of cables in tables
such as the one shown
on the right. Each of
these tables pertain to a
specific type of cable
construction (e.g. copper
 conductor, PVC
insulated, 0.6/1kV
voltage grade, etc) and a
base set of installation
conditions (e.g. ambient
temperature, installation
method, etc). It is
important to note that the
current ratings are only
valid for the quoted types
of cables and base
installation conditions.
In the absence of any
guidance, the
following reference based
current ratings may be
used.
Installed Current
Ratings
When the proposed
installation conditions
differ from the base
conditions, derating (or
correction) factors can be
applied to the base
current ratings to obtain
the actual installed
current ratings.
International standards
and cable manufacturers
will provide derating
factors for a range of
installation conditions, for
example ambient / soil
temperature, grouping or
bunching of cables, soil
thermal resistivity, etc.
The installed current
rating is calculated by
multiplying the base
current rating with each
of the derating factors,
i.e.
[math]I_{c} = I_{b} . k_{d} \,[/math]
where [math]I_{c}\,
[/math] is the
installed current
rating (A)
[math]I_{b}\,[/math] is the base current rating (A)
[math]k_{d} \,[/math] are the product of all the derating
factors
For example,
suppose a cable
had an ambient
temperature
derating factor
of [math]k_{amb}
=
0.94[/math] and
a grouping
derating factor
of [math]k_{g} =
0.85[/math], then
the overall
derating
factor [math]k_{d
} = 0.94 x 0.85 =
0.799[/math]. For
a cable with a
base current
rating of 42A, the
installed current
rating would
be [math]I_{c} =
0.799 x 42 =
33.6A[/math].
In the absence of
any guidance,
the
following referen
ce derating
factors may be
used.
Cable Selection
and
Coordination
with Protective
Devices
Feeders
When sizing
cables for non-
motor loads, the
upstream
protective device
(fuse or circuit
breaker) is
typically selected
to also protect
the cable against
damage
 from thermal
overload. The
protective device
must therefore
be selected to
exceed the full
load current, but
not exceed the
cable's installed
current rating,
i.e. this inequality
must be met:
[math]I_{l} \leq I_{p} \leq I_{c} \, [/math]
Where [math
]I_{l} \,
[/math] is the
full load
current (A)
[math]I_{p} \, [/math] is the protective device rating (A)
[math]I_{c} \, [/math] is the installed cable current rating (A)
Motors
Motors
are
normally
protecte
d by a
separate
thermal
overload
(TOL)
relay
and
therefore
the
upstrea
m
protectiv
e device
(e.g. fus
e or
circuit
breaker)
is not
required
to
protect
the cable
against
overload
s. As a
result,
 cables
need
only to
be sized
to cater
for the
full load
current
of the
motor,
i.e.
[math]I_{l} \leq I_{c} \, [/math]
Whe
re [m
ath]I
_{l} \,
[/mat
h] is
the
full
load
curre
nt
(A)
[math]I_{c} \, [/math] is the installed cable current rating (A)
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:

 Current flow through the cable – the higher the current

flow, the higher the voltage drop
 Impedance of the conductor – the larger the
impedance, the higher the voltage drop
Ca
ble
Im
pe
da
nc
es
Th
e
im
pe
da
nc
e
of
the
ca
ble
is a
fun
ctio
n
of
the
ca
ble
siz
e
(cr
oss
-
sec
tio
nal
are
a)
an
d
the
len
gth
of
the
ca
ble
.
Mo
st
ca
ble
ma
nuf
act
ure
rs
will
qu
ote
a
ca
ble’
s
res
ista
nc
e
an
d
rea
cta
nc
e
in [
ma
th]\
O
me
ga[
/m
ath
]/k
m.
Th
e
foll
owi
ng 
typi
cal
ca
ble
im
pe
da
nc
es 
for
low
volt
ag
e
AC
an
d
DC
sin
gle
cor
e
an
d
mu
ltic
ore
ca
ble
s
ca
n
be
us
ed
in
the
ab
se
nc
e
of
an
y
oth
er
dat
a.
Cal
cul
ati
ng
Vol
tag
e
Dr
op
For
AC
sys
te
ms
,
the
me
tho
d
of
cal
cul
ati
ng
volt
ag
e
dro
ps
ba
se
d
on
loa
d
po
we
r
fac
tor
is
co
m
mo
nly
us
ed.
Ful
l
loa
d
cur
ren
ts
are
nor
ma
lly
us
ed,
but
if
the
loa
d
ha
s
hig
h
sta
rtu
p
cur
ren
ts
(e.
g.
mo
tor
s),
the
n
volt
ag
e
dro
ps
ba
se
d
on
sta
rtin
g
cur
ren
t
(an
d
po
we
r
fac
tor
if
ap
 plic
abl
e)
sh
oul
d
als
o
be
cal
cul
ate
d.
For
a
thr
ee
ph
as
e
sys
te
m:
[math] V_{3\phi} = \frac{\sqrt{3} I (R_{c} \cos\phi + X_{c}
\sin\phi) L}{1000} \, [/math]
Where 
[math]
V_{3\p
hi} \,
[/math] 
is the
three
phase
voltage
drop
(V)
[math] I \, [/math] is the nominal full load or starting current
as applicable (A)
[math] R_{c} \, [/math] is the ac resistance of the cable
([math]\Omega[/math]/km)
[math] X_{c} \, [/math] is the ac reactance of the cable
([math]\Omega[/math]/km)
[math] \cos\phi \, [/math] is the load power factor (pu)
[math] L \, [/math] is the length of the cable (m)
For a single
phase
system:
[math] V_{1\phi} = \frac{2 I (R_{c} \cos\phi + X_{c} \sin\phi)
L}{1000} \, [/math]
 Where [math]
V_{1\phi} \,
[/math] is the
single phase
voltage drop
(V)
[math] I \, [/math] is the nominal full load or starting current
as applicable (A)
[math] R_{c} \, [/math] is the ac resistance of the cable
([math]\Omega[/math]/km)
[math] X_{c} \, [/math] is the ac reactance of the cable
([math]\Omega[/math]/km)
[math] \cos\phi \, [/math] is the load power factor (pu)
[math] L \, [/math] is the length of the cable (m)
For a DC system
[math] V_{dc} = \frac{2 I R_{c} L}{1000} \, [/math]
Where [math] V_
[/math] is the dc
drop (V)
[math] I \, [/math] is the nominal full load or starting current
as applicable (A)
[math] R_{c} \, [/math] is the dc resistance of the cable
([math]\Omega[/math]/km)
[math] L \, [/math] is the length of the cable (m)
Maximum Perm
Voltage Drop
It is customary f
standards (or cli
specify maximum
permissible volta
which is the high
drop that is allow
a cable. Should
exceed this volta
then a larger cab
should be select
Maximum voltag
across a cable a
because load co
(e.g. appliances
an input voltage
range. This mea
the voltage at th
is lower than its
minimum voltag
appliance may n
correctly.
 In general, most
equipment will o
normally at a vo
as 80% nominal
For example, if t
voltage is 230VA
most appliances
>184VAC. Cable
typically sized fo
conservative ma
voltage drop, in
5 – 10% at full lo
Calculating Ma
Cable Length d
Voltage Drop
It may be more c
to calculate the
length of a cable
particular condu
given a maximu
permissible volta
(e.g. 5% of nom
at full load) rathe
voltage drop itse
example, by doi
possible to cons
showing the ma
lengths correspo
different cable s
to speed up the
similar type cabl
The maximum c
that will achieve
calculated by re
the voltage drop
and substituting
maximum permi
voltage drop (e.g
415V nominal vo
20.75V). For a th
system:
[math] L_{max} = \frac{1000 V_{3\phi}}{\sqrt{3} I (R_{c}
\cos\phi + X_{c} \sin\phi)} \, [/math]
Where [math] L_
[/math] is the ma
of the cable (m)
[math] V_{3\phi} \, [/math] is the maximum permissible
three phase voltage drop (V)
[math] I \, [/math] is the nominal full load or starting current
as applicable (A)
[math] R_{c} \, [/math] is the ac resistance of the cable
([math]\Omega[/math]/km)
[math] X_{c} \, [/math] is the ac reactance of the cable
([math]\Omega[/math]/km)
[math] \cos\phi \, [/math] is the load power factor (pu)
For a single pha
[math] L_{max} = \frac{1000 V_{1\phi}}{2 I (R_{c} \cos\phi +
X_{c} \sin\phi)} \, [/math]
Where [math] L_
maximum length
[math] V_{1\phi} \, [/math] is the maximum permissible
single phase voltage drop (V)
[math] I \, [/math] is the nominal full load or starting current
as applicable (A)
[math] R_{c} \, [/math] is the ac resistance of the cable
([math]\Omega[/math]/km)
[math] X_{c} \, [/math] is the ac reactance of the cable
([math]\Omega[/math]/km)
[math] \cos\phi \, [/math] is the load power factor (pu)
For a DC system
[math] L_{max} = \frac{1000 V_{dc}}{2 I R_{c}} \, [/math]
Where [math] L_
length of the cab
[math] V_{dc} \, [/math] is the maximum permissible dc
voltage drop (V)
[math] I \, [/math] is the nominal full load or starting current
as applicable (A)
[math] R_{c} \, [/math] is the dc resistance of the cable
([math]\Omega[/math]/km)
[math] L \, [/math] is the length of the cable (m)
Step 4: Shor
During a short c
flow through a c
current flow cau
cable. High temp
reactions in the
and other compo
degrade the con
sectional area o
higher fault curre
Therefore, cable
largest short circ
Minimum Cable
Temperature R
 The minimum ca
temperature rise
equation of the f
[math] A = \frac{\sqrt{i^{2}t}}{k} \, [/math]
Where [math]A \
area of the cable
[math]i \, [/math] is the prospective short circuit current (A)
[math]t \, [/math] is the duration of the short circuit (s)
[math]k \, [/math] is a short circuit temperature rise
constant
The temperature
material propert
conductor tempe
international sta
temperature rise
60364-5-54 calc
[math] k = 226 \sqrt{ \ln \left( 1 + \frac{\theta_{f}-\theta{i}}
{234.5 + \theta_{i}} \right) } \, [/math] (for copper
conductors)
[math] k = 148 \sqrt{ \ln \left( 1 + \frac{\theta_{f}-\theta{i}}
{228 + \theta_{i}} \right) } \, [/math] (for aluminium
conductors)
Where [math]\th
(deg C)
[math]\theta_{f} \, [/math] is the final conductor temperature
(deg C)
Initial and Fina
The initial condu
operating tempe
typically chosen
general, the cab
temperature and
As a rough guid
different insulati

Short Circuit E
The short circuit
maximum short
However for circ
then the short ci
 let-through ener
manufacturer da
Step 5: Earth
Sometimes it is
impedance of a
fault occurs betw
fault, it is desirab
the fault within a
any inadvertent
Ideally the circui
protection will be
time. The maxim
touch voltage do
For most circuits
though for porta
time is desirable
However for circ
protective device
maximum discon
fault current due
cause the protec
time. For examp
maximum discon
fuse melting cur
fuse time-curren
By simple applic
[math] I_{A} = \frac{V_{0}}{Z_{s}} \, [/math]
Where [math] I_
protective device
[math] V_{0} \, [/math] is the phase to earth voltage at the
protective device (V)
[math] Z_{s} \, [/math] is the impedance of the earth fault
loop ([math]\Omega[/math])
It can be seen fr
must be sufficien
protection.
The Earth Fault
The earth fault lo
conductor, inclu
facility. However
consists only of
The earth fault lo
[math] Z_{s} = Z_{c} + Z_{e} \, [/math]
Where [math] Z_
[math] Z_{c} \,[/math] is the impedance of the active
conductor ([math]\Omega[/math])
[math] Z_{e} \,[/math] is the impedance of the earth
conductor ([math]\Omega[/math])
Assuming that th
impedance can
[math] Z_{s} = \frac{L}{1000} \sqrt{(R_{c}+R_{e})^{2} +
(X_{c}+X_{e})^{2}} \, [/math]
Where [math] L
[math] R_{c} \,[/math] and [math] R_{e} \,[/math] are the ac
resistances of the active and earth conductors respectively
([math]\Omega[/math]/km)
[math] X_{c} \,[/math] and [math] X_{e} \,[/math] are the
reactances of the active and earth conductors respectively
([math]\Omega[/math]/km)
Maximum Cabl
The maximum e
[math] Z_{s,max} = \frac{V_{0}}{I_{A}} \, [/math]
Where [math] Z_
[math] V_{0} \, [/math] is the phase to earth voltage at the
protective device (V)
[math] I_{A} \, [/math] is the earth fault current required to
trip the protective device within the minimum disconnection
time (A)
The maximum c
[math] L_{max} = \frac{1000 V_{0}}{I_{A} \sqrt{(R_{c}
+R_{e})^{2} + (X_{c}+X_{e})^{2}}} \, [/math]
Where [math] L_
[math] V_{0} \, [/math] is the phase to earth voltage at the
protective device (V)
[math] I_{A} \, [/math] is the earth fault current required to
trip the protective device within the minimum disconnection
time (A)
[math] R_{c} \,[/math] and [math] R_{e} \,[/math] are the ac
resistances of the active and earth conductors respectively
([math]\Omega[/math]/km)
[math] X_{c} \,[/math] and [math] X_{e} \,[/math] are the
reactances of the active and earth conductors respectively
([math]\Omega[/math]/km)
Note that the vo
voltage, but usu
represented by a
[/math] = 0.8 can
[math]V_{0} = c V_{n} = 0.8 V_{n} \,[/math]
Where [math]V_
 Worked Ex
In this example,
Step 1: Data
The following da

 Cable type: Cu/PVC/GSWB/PVC, 3C+E, 0.6/1kV

 Operating temperature: 75C
 Cable installation: above ground on cable ladder
bunched together with 3 other cables on a single layer
and at 30C ambient temperature
 Cable run: 90m (including tails)
 Motor load: 37kW, 415V three phase, full load current
= 61A, power factor = 0.85
 Protection: aM fuse of rating = 80A, max prospective
fault [math]I^{2}t[/math] = 90 [math]A^{2}s[/math] , 5s
melt time = 550A
Step 2: Cable
Suppose the am
The overall dera
25 [math]mm^{2
cable should be
The installed cu
58.38A and 0.72
then the installe
continuous use
exceeds the mo
Step 3: Volta
Suppose a 25 [m
for a run length
A 25 [math]mm^
0.0895 [math]\O
[math] V_{d} = \frac{90}{1000} \times \sqrt{3} \times 61
\times \left[ 0.884 \times 0.85 + 0.0895 \times \sin(\cos^{-1}
(0.85) \right] = 7.593V \, [/math]
A voltage drop o
voltage dorp of 5
Step 4: Shor
The cable is ope
What is the mini
PVC has a limiti
minimum cable
[math]A = \frac{\sqrt{90,000}}{111.329} = 2.695 mm^{2} \,
[/math]
 In this example,
adiabatic period
cable can withst
short circuit tem
[math]A = \frac{\sqrt{550^{2} \times 5}}{111.329} = 11.047
mm^{2} \, [/math]
Therefore, our 2
Step 5: Earth
Suppose there i
Suppose that th
is 5s, is our 90m
The 80A motor f
0.884 [math]\Om
0.0895 [math]\O
The maximum le
[math] L_{max} = \frac{(1000)(0.8)(240)}{550
\sqrt{(0.884+2.33)^{2} + (0.0895+0.0967)^{2}}} =
108.43m \, [/math]
The cable run is
our 25 [math]mm

Waterfall C

Table 2. Example

Sometimes it is
instead of havin
These charts are
each cable size.
is blacked out on
Preparing a wat
selection.

Internation
IEC
IEC 60364-5-52
the IEC standard
NEC
NFPA 70 (2011)
sizing in Article 3
BS
BS 7671 (2008)
Kingdom.
AS/NZS
AS/NZS 3008.1
standard govern
3008.1.2 is for N

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