Ref. (Department/Year/Serial No.

Work-Report
Subject/Title Place Date
Dimensioning of DC Power Cables Offenbach 2004-03-18
220V and 24V Author (s) Department Tel. Signature

Nitsche G132 2954 sgd.Nitsche

Project
Signature for Release by Dept. Concerned Signature for External Release by
(for Contents, Handling, Distribution) Sales & Marketing Dept. (Not
NUBARIA POWER STATION I&II Required for Approval Documents)

Handling Instruction
restricted sgd. Huber (G132)
Export Classification AL: ECCN:
Proj.-Code UA Contents Code Doc. Ident. No. UNID

EGY261 BN02 7082 02 10621967

Summary*) Pages of 9 Appendices -
Text

This report determines the permissible lengths per cross-section for the 220V DC and
24V DC Systems with respect to the thermal load conditions and permissible voltage drop.

Table of Contents Page

1. Thermal stresses 3
2. Voltage Drop of 220V DC Supply Cables 4
3. Voltage Drop of 220V Feeder Cabling 6
4. Voltage Drop of 24V DC Feeder Cabling 6

Table 1 Symbols 7
Table 2 220V DC Feeder cable dimensioning 8
Table 3 24V DC Feeder cable dimensioning 9

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Approval and Release Sheet

Department Responsible Date Name Signature or "signed by"

Domain

PG G132 Electrical Systems 2004-03-18 Nitsche Signed by Nitsche

Approval / Release

PG G132 Electrical Systems 2004-03-18 Huber Signed by Huber

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CABLE DIMENSIONING FOR THE 220V AND 24V DC CONSUMERS

1. Thermal stresses

For accumulation of cables (warming up each other) or divergent ambient temperatures the
current carrying capacity Iz has to be reduced.

I z' = I z
* f total

This adaptation of the current carrying capacity has to be done by derating factors for
accumulation and temperature:

Conversion factor for 50°C air temperature as shown in table 4:

XLPE cable f = 0.82

T

The worst case for accumulation of DC-cable is considered with cables laid on
4 trays side by side according to DIN VDE 0276-1000

f = 0.68
H

XLPE cable f = f ∗ f = 0.56

total T H

The short circuit currents of the batteries are very low, so that the thermal stresses in case
of a short circuit can be neglected for the dimensioning of the cable.

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2. Voltage Drop of 220V DC Supply Cables

In order to calculate the 220V DC supply cables, the permissible voltage drop on the cable
lengths from the battery (battery operation) and from the battery charger (battery charger
operation) to the DC consumers, have to be considered.
With the following the maximum cable length and the different operating conditions are
given.

Charger operation Battery operation

Float charge voltage Minimum voltage after

1 hour operation
U = 2.23V per cell U = 1.83V per cell
108 x 2.23V = 240.84V 108 x 1.83V = 197.64V

Rated current Battery capacity

Ir = 63A 192Ah

Total cable length Total cable length

Charger to Switchgear Battery to Switchgear
via charger

5m 10m

For the supply cables of the 220V DC system from Charger/Battery to Switchgear the cable
1kV 1 x 120 mm² is provided.

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With the following equation the permissible voltage drop is calculated.

χ 70 * A ∆U
l= *( − RB )
2 Ir

2 * Ir χ * A * RB
 ∆U = * (l + 70 )
χ 70 * A 2

Charger operation

Functional Area ID-Code Ir χ 70 A l RB ∆U

GT Part 11-12BTL10 63A . m mm²Ω
485 1 x 120mm² 5m 0,0002Ω 0.12V

Battery operation

Functional Area ID-Code Ir χ 70 A l RB ∆U

GT Part 11-12BTA10 63A . m mm²Ω
485 1 x 120mm² 10m 0,0002Ω 0.22V

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3. Voltage Drop of 220V Feeder Cabling

The allowable voltage drop on the consumer cabling is according to the minimum battery
voltage after 1h operation. Taking into consideration a lowest acceptable voltage of 187V
(85%) at the consumer a below mentioned voltage drop between the 220V DC LV-
switchgear and the consumer is allowed.

Functional Area ID-Code ∆U

GT Part BUB; BUC 10.42V

For the cable length between the SWGR-cubicles and the consumers the above mentioned
voltage drops have been observed. This means a total voltage drop of 10.64V. Therefore
the voltage drop is in the permissible limit of 5% related to the nominal voltage.

The cable length for feeder cabling dependant on above mentioned voltage drop is
calculated with:

χ *A ∆U
l max
= 90
*( − RB ) ;χ = 45.45 m mm²Ω ; A and Ia as per table 2.
2 I a
90

4. Voltage Drop of 24V DC Feeder Cabling

For the 24V DC Feeder Cabling, the calculation is nearly the same as above.

The output voltage of the 220V/24V, DC/DC converter is 26V stabilized, at an input voltage
range of 187 - 242V.

For cable dimensioning a voltage drop of

- ∆U = 3V from the DC/DC converters to the consumers

is considered.

The cable length for feeder cabling dependant on above mentioned voltage drop is
calculated with:

χ *A ∆U
l max
= 90
*( − RB ) ;χ = 45.45 m mm²Ω ; A and Ia as per table 3.
2 I a
90

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Table 1: Symbols

∆U V permissible voltage drop

l m permissible cable length

l max
m maximum permissible cable length
RB Ω resistance of protective device and contact resistance
I Z
A current carrying capacity of the cable at 30°C
'
I Z
A reduced carrying capacity of the cable due to divergent ambient conditions
Ia A MCB current
Ir A rated current
f H
derating factor for accumulation of cable

f T
derating factor for other ambient temperature
f total total derating factor
χ 70 electrical conductivity for PVC cable
χ 90 electrical conductivity for XLPE cable
A mm² conductor cross-section

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Table 2: 220V DC Feeder cable dimensioning

Maximum permissible cable length l max

(m)
'
Taking into consideration a reduced current carrying capacity of the cable I Z
and a worst allowable voltage drop of ∆U = 10.42V for GT the cable sizes are as
follows:

MCB- current I a ( A) 6 16 32 50 125

'
Cable size A (mm² ) I Z
( A) I Z
( A) l max
(m)
2,5 26 15,6 94
4 34 20,4 150 59
6 44 26,5 225 84
10 61 36,6 375 140 70
16 82 49,6 600 225 112
25 108 64,8 938 351 175 112
35 135 81,0 1313 492 246 157
50 168 100,8 1876 703 351 224 89
70 207 124,2 2627 984 492 314 125

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Table 3: 24V DC Feeder cable dimensioning

Maximum permissible cable length l max

(m)
'
Taking into consideration a reduced current carrying capacity of the cable I Z
and a worst allowable voltage drop of ∆U = 3V the cable sizes are as follows:

MCB- current I a ( A) 6 10 16 20 32 50
'
Cable size A (mm² ) I Z
( A) I Z
( A) l max
(m)
2,5 26 14,8 28 17
4 34 19,4 45 27 17
6 43 24,5 68 40 25 20
10 59 33,6 113 68 42 34 21
16 78 44,5 181 109 68 54 34
25 105 59,6 283 170 106 85 53 33
2 x 25 210 119,7 567 340 212 170 106 67

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