Sizing Cables, Conduit and Trunking

Sizing Cables, Conduit
and Trunking
Learner Work Book
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LEARNER WORK BOOK
Sizing Cables Conduit and Trunking REV4.1 2

LEARNER WORK BOOK
Table of Contents
Foreword ........................................................................................................4
Sizing Cables, Conduit and Trunking Unit Overview..................................6

Practical Skills .................................................................................................... 6
Knowledge Requirements .................................................................................. 6
The price of cable ..........................................................................................7
Cable calculation process.............................................................................8

Design Current – I b ........................................................................................... 9
Over-Current Protective Device – I n................................................................ 11
Reference Methods.......................................................................................... 12
Reference Methods.......................................................................................... 13
Correction Factors.......................................................................................15
Ambient temperature - Ca ................................................................................ 16
Thermal Insulation - Ci ..................................................................................... 17
Thermal Insulation - Ci ..................................................................................... 18
Grouping circuits - Cg....................................................................................... 20
Protection by BS3036 semi-enclosed (re-wireable) fuses - Cc ......................... 22
The effects of volt drop ...............................................................................23

What is volt drop? ............................................................................................ 23
How to establish the value of volt drop ............................................................. 24
Shock protection..........................................................................................27
Earth fault loop impedance and fault current .................................................... 27
Earth Loop Impedance ..................................................................................... 28
The earth fault loop path .................................................................................. 29
What value is acceptable? ............................................................................... 29
How is earth loop impedance calculated? ........................................................ 31
Earth fault current............................................................................................. 34
Time / current characteristics and disconnection times..................................... 36
Thermal Constraints ....................................................................................38

Minimum size of c.p.c....................................................................................... 40
Cable capacities of conduit and trunking ..................................................44

Conduit Capacities ........................................................................................... 44
Trunking capacities .......................................................................................... 46
Maximum demand and diversity.................................................................48

Maximum Demand ........................................................................................... 48
Diversity ........................................................................................................... 49

LEARNER WORK BOOK
Foreword
When trying to determine the size of conductors necessary for the safe working of a
circuit many factors need to be considered. It is not acceptable to guess or to use
cable sizes that are in common usage just because someone may say that you
should use 1.5mm² ‘twin and earth’. They may just be wrong! If you get cable sizes
wrong, then there may be a fire risk, a load that won’t function properly, or you may
be wasting money on excessive material.
All cables have electrical resistance, so there must be an energy loss when
they carry current. This loss appears as heat and the temperature of the cable
rises. As it does so, the heat it loses to its surroundings by conduction,
convection and radiation also increases. The rate of heat loss is a function of
the difference in temperature between the conductor and the surroundings, so
as the conductor temperature rises, so does its rate of heat loss.
As we have already discovered previously copper is a very good electrical conductor.

This means that the resistance of a length of copper cable is relatively low. An
aluminium cable would have nearly twice the resistance of a copper cable with the
same dimensions. Therefore the energy losses in the aluminium cable will be higher
than in the copper cable. The copper cable is more energy efficient.
To make an aluminium cable with the same energy losses as a copper cable, we
have to make it larger. The larger cross sectional area reduces its resistance and
brings the energy losses down to the same as a narrower copper cable.
Al and Cu Comparison for 500A cable
The two cables in the photograph have similar current-carrying capacity. They are
each designed to be able to carry up to 500A without the conductor going above
90°C. The copper cable (on the right) is thinner than the aluminium one, because
copper is a better conductor. Its cross sectional area is 300mm2 as opposed to
500mm2 for the aluminium.

LEARNER WORK BOOK
Cables are designed to be able to withstand a certain amount of heat, and this ability
depends on the type of insulation that is used and how the cables are installed into a
wiring system. When we consider the current carrying capacity we have to ensure
that the cable won’t overheat when the normal current is flowing. If conductors are
installed into wiring systems that are incorrectly sized they will not be able to “lose” enough
heat and could have an affect on the insulation properties.
This will be looked at in more detail when we take a look at cable calculations and
sizing of conduit and trunking.
Cable calculation is the method used to ensure that all the factors of a
circuit have been taken into consideration, in particular, the operating
current of a cable that is determined by how hot the cable gets. This is
affected by a number of variables:
• The resistance of the cable - a higher resistance cable will get hotter at
a given current.
• The insulation on the cable - this will tend to keep it warm like a jacket.
• The environment of the cable - if it is in a duct with other cables
(especially with no airflow) it will tend to get hotter.
This workbook is to be accompanied by PowerPoint

“Sizing Cables Conduit and Trunking”

LEARNER WORK BOOK
Sizing Cables, Conduit and Trunking Unit Overview
Practical Skills
To achieve the learning outcome the candidate must be able to:
Calculate cable sizes for circuits to ensure overload ratings, voltage drop,
shock protection and thermal constraints are all met in accordance with
BS7671
Knowledge Requirements
To achieve the learning outcome the candidate must know:
How to select a suitably sized cable including:

How to calculating the current demand of single and three line circuits
Select the correct rating of protective device
How to allow and apply factors for:
Grouping
Thermal insulation
Ambient temperature
Protective device type
How to check that the voltage drop is not excessive
Establishing circuit disconnections times are met
Thermal constraints are satisfied
How to determine the size of conduit and trunking appropriate to the size and
number of cables
Methods used of establishing a circuit’s maximum demand after diversity is
applied

LEARNER WORK BOOK
The price of cable

Before we look at different cable sizes let us gain some appreciation for the price of
cable. As you can imagine the cost of cable varies according to the amount of
materials and manufacturing needed to construct it. Basically the more copper the
more pennies.
Shown below is a table with various prices for one particular type of cable. See how
the price varies from size to size? Also note that the price per metre is more than the
calculated amount for 100 metres.
What reason could you give to explain why buying 100 metres costs less than buying five
coils of twenty metres?
Size and number of cores £ - Price per metre £ - Price per 100 metres
4 core 1.5mm² XLPE / SWA 1.11 93.99

4 core 2.5mm² XLPE / SWA 1.52 126.00
4 core 4.0mm² XLPE / SWA 2.15 179.99
4 core 6.0mm² XLPE / SWA 3.00 251.99
4 core 10.0mm² XLPE / 4.40 385.00
SWA
4 core 16.0mm² XLPE / 6.10 550.00
SWA
Cable prices as of JULY 2008
Complete the following exercise.

The following lengths of XLPE/ SWA are required for a job. Your job as the company’s buyer is
to process this order form from the site supervisor. The client has requested a price of the
materials before they will let the job go ahead. Work out the prices using the table above
Price (£)
1. 50M of 4 core 1.5mm² XLPE / SWA in one coil
2. 200M of 4 core 1.5mm² XLPE / SWA in two coils
3. 100M of 4 core 16.0mm² XLPE / SWA in five coils
4. 100M of 4 core 16.0mm² XLPE / SWA in one coil
How might the price be reduced to add a further saving in cost to the job?

LEARNER WORK BOOK
Cable calculation process

Cable selection can be defined as the ‘rules’ that you must follow when deciding
which cable to choose for any installation.
This unit will consider the following areas used in cable selection:
External influences Application of correction factors

Design current (Ib) Voltage drop
Rating of the protective device Shock protection
(In) Thermal constraints
Reference methods Diversity.
Correction factors (Ca, Ci, Cg,
Cc)
External influences
If the circuit is to be installed in a hot or wet environment then the cable has to be
suitably rated and sealed from any affecting factors. If the environment carries a high
risk of mechanical damage the cable or installation will have to be sufficiently
protected form danger. Once you have decided on the type of cable suitable for the
environmental conditions, you must choose the size of conductor to be used.
In order to gain appreciation for cable selection will only take a look at the various
current ratings of various sizes of XLPE armoured cable.
The Basics
So that we can understand a full cable calculation we must first understand the
basics. Listed below are four terms that describe vital information used in the
calculation process. Try to remember them, as they will appear frequently throughout
this course.
I b - term used to describe a circuit’s design current in amps i.e. the load.
I n - term used to describe a circuit’s protection size in amps i.e. the fuse size.
I z - term used to describe a circuit’s value, in amps, once all de-rating factors have been
considered
I t - term used to describe the tabulated current rating of a cable in amps i.e. the current a cable
can safely carry.
Ib ≤ In ≤ Iz ≤ It
The formula above states the underlying principle of the calculation of a circuit’s
cable size. The first factor you need to consider is design current.

LEARNER WORK BOOK
Design Current – I b
The first stage of the design process is to determine how much current will flow in the
circuit. This current is known as the design current and is the full load current of the
circuit. It is calculated using one of the formulae below depending on the type of load.
You need to ensure all units have to be calculated at the same value (i.e. kW have to
be divided by kV; W have to be divided by V)
Where: I = the design current in amps (A)

P = the circuit power in watts (W)
V = the circuit voltage in volts (V)
Cos Φ = the power factor
Resistive loads
The following formulae apply to single and three line supplies:
P P
I= I=
V 3 ×V
Single-line
230v Three line 400v
Resistive Resistive
Inductive and / or capacitive loads

The following formulae apply to single and three line supplies:
P P
I= I=
V × cos Φ 3 × V × cos Φ
Single-line 230v
Inductive and or Three line 400v
Capacitive Inductive and or Capacitive
In a.c. circuits, the effects of either highly inductive or highly capacitive loads can
produce a poor power factor (cos Ф) (inductive and capacitive loads will be explained
later). For now it is satisfactory to know that in circuits where there are inductive and
electronic components such as coils and capacitors there are losses. These losses
slightly increase the amount of current the equipment uses. You will have to allow for
this in such circuits. Note √3 = 1.732

LEARNER WORK BOOK
Example 1.
A single-line lighting circuit has a total power consumption of 2000 watts using 100-
watt filament lamps. Calculate the design current.
i) Select the correct formula. (Single line; 230v, resistive)
P
I=
V
ii) Input the data into the formula and work it out to two decimal places and be sure to
add the unit (A).
2000
I= = 8.70 A
230
Example 2.
A three-line inductive load has a total power consumption of 30,000 watts (30kW)
with a power factor of 0.95. Calculate the design current.
i) Select the correct formula. (Three line; 400v, inductive)
P
I=
3 × V × cos Φ
ii) Input the data into the formula and work it out to two decimal places and be sure to
add the unit (A).
30000
I= = 45.58 A
3 × 400 × 0.95
There are a few examples for you to calculate for yourself shortly.

LEARNER WORK BOOK
Over-Current Protective Device – I n
Once the design current has been established we must then select an over-current
protective device. The function of an over-current protective device is basically as it’s
name suggests to protect the circuit from over-current and of course, faults. It is the
weakest part of the circuit and should operate in a given time so that only a limited
amount of harm or danger, to persons, livestock or property, will exist under fault
conditions. The two main factors to consider when selecting a device are shown
below.
'Over current' means what it says - a greater level of current than the
materials in use will tolerate for a long period of time. The term can be divided
into two types of excess current. 1. Overload current and 2. Fault current
1 Amount of Overload current
These are currents higher than those intended to be present in the system. If such
currents persist they will result in an increase in conductor temperature, and hence a
rise in insulation temperature. High conductor temperatures are of little consequence
except that the resistance of the conductor will be increased leading to greater levels
of voltage drop.
Insulation cannot tolerate high temperatures since they will lead to deterioration and
eventually failure. The most common insulation material is p.v.c. If it becomes too hot
it softens, allowing conductors, which press against it and possibly pass through it.
Overload currents occur in circuits which have no faults but are carrying a higher
current than the design value due to overloaded machines, an error in the
assessment of diversity, and so on.
2 Amount of Fault current
These currents will only occur under fault conditions, and may be very high indeed.
As we shall shortly see such currents will open the protective devices very quickly.
These currents will not flow for long periods but under such short-term circumstances
the temperature of p.v.c. Insulation may rise to 160°C.
The temperature of two conductors at the point of a fault can be as high as

300°C. This is why the conductors and or the cutting tool used will melt at
the point of the fault.
Device Selection
The protective device current rating must be equal to or next largest size so that
the circuit is sufficiently protected. Take a look at the formula used for the cable
calculation process again below.
Ib ≤ I n then I z ≤ It
You can see from this that:
The over-current protective device must be equal to or greater than the design
current.

LEARNER WORK BOOK
What reasons can you state for the protective device being equal to or slightly larger than the
design current? You may be required to read your reasons to the class.
There are many protective devices in existence and these will be looked at in more
detail in Unit 4.4. What is important for now is to realise that these devices all have
different ratings or current ratings. Shown below is part of BS7671 that shows the
different ratings of BS88 fuses from 6A to 200A.
Fuse sizes of BS88 over-current protective devices (Amps)
6 10 16 20 25 32 40 50 63 80 100 125 160 200
Using the table above and a calculator see if you can work out the design currents and over-
current protection size (BS88) of each of the circuits listed.
Ib In
1. A single line, resistive lighting circuit

with a total power of 1200 watts
2. A single line heating circuit with a total

power of 6KW
3. A single line, inductive lighting circuit

with a total power of 1200 watts and
power factor of 0.85
4. A three line heating system with a total

power of 10KW watts
5. A single-line supply to a 100A

consumer unit expected to carry 48
amps maximum.

LEARNER WORK BOOK
Reference Methods
Table 4A2 from the IEE Wiring Regulations lists the common methods that can be
used to install a cable.
You need to decide at this stage in the cable selection process which method of
installation to use. This will make sure that the correct cable column is chosen in the
later stages of cable selection.
This choice is also important when you calculate correction factors for thermal
insulation.
Using the table (4E4A) from BS7671 on the next page, see if you can determine the basic
current ratings (tabulated current ratings I t) of the cables below. Be sure to fully observe the
details so you choose the correct column.
NB: This exercise displays how different sizes of cables can carry different amounts of current.
Also considered are the circuit’s installation types.
It
1. A 4.0mm², two core cable, carrying alternating

current that has been clipped to a wall.
2. A 10.0mm², four core cable, carrying A.C current

ran on a cable tray
3. A 16.0mm², single line cable supplying a

consumer unit, clipped direct
4. A 25.0mm², three line and neutral supply for an

uninterruptible power supply unit in an office
block clipped direct to a wall.
5. A 25.0mm², three line and neutral (TP&N)

supply to a control panel, ran on a cable tray
Consider your findings and try to explain the reasons why we sometimes need to select
different sized cables. You may be required presenting your reasons to the class

LEARNER WORK BOOK
Appendix 4 of BS7671 contains tables for each type of conductor type from single
core PVC to multi-core paper insulated lead steel wire armoured. Please refer to
BS7671 for more information.
C E

LEARNER WORK BOOK
Correction Factors
You, as the ‘designer’ of the installation, need to know the different correction factors,
know where they are required and then apply these to the nominal rating of the
protection (In) to obtain a value for Iz. Once Iz is calculated we then refer to the
correct cable tables from BS7671and select the size based upon the next highest
tabulated value (It).
Temperature can have a serious effect on a circuit. It can increase the risk of a fault,
can cause a cable’s insulation to melt and can even cause an electrical fire. There
are various factors that form a circuit’s temperature and we will look at these in more
detail below. It is essential to follow the correct design procedures and apply the
correct correction factors to ensure that the many effects of temperature do not affect
the normal operation of a circuit. We will look at these factors individually below but
remember there may be more than one factor present in one installation.
Ca – Ambient Temperature (the surrounding temperature the circuit will operate in)
Ci – Thermal Insulation (the existence and contact of thermal insulation with the cct)
Cg – Grouping of ccts (whether or not the circuit is “bunched” with other circuits)
Cc – Protection type (whether or not the circuit is supplied with a BS3036 fuse or not.
What If More Than One Factors Are Present?
If more than one correction factor is present they can be considered in one
calculation shown below
In
Iz =
Ca × Ci × Cg × Cc
Example
A three line, 32A circuit is to be installed using XLPE SWA. It will run through a boiler
house clipped direct to a wall where the ambient temp will be 40ºC. It is not grouped
nor does it come into contact with any thermal insulation. Discover the “de-rated”
value i.e. the minimum permissible rating of cable.
i) Establish all the correction factors present and obtain the values from the
tables in the regulations.
Ca=0.91; Ci=n/a; Cg=n/a; Cc=n/a

(Where there is no factor present we assume a value of one).
ii) Input the values into the formula and work out Iz to two decimal places and
include the value (A)
32
Iz = = 35.16 A
0.91 × Ci × Cg × Cc
iii) Select the correct cable table then select the correct column based upon
the reference method and select the next highest value (or equal) to Iz.
Table 4E4A; column 3; value of 42 amps corresponds to a 4mm² XLPE SWA cable.

LEARNER WORK BOOK
Ambient temperature - Ca
This is the temperature of the surroundings of

the cable, often the temperature of the air in a
room or building in which the cable is installed.
When a cable carries current, it gives off heat.
Therefore the hotter the surroundings of the
cable, the more difficult it is for the cable to get
rid of this heat. But if the surrounding
temperature is low, then the heat given off
could be easily let out and the cable could carry more current. Cables must give off
this heat safely or they could be damaged and there is a risk of a fire. You can find
the correction factor for ambient temperature in Tables 4B1 and 4B2 of the IEE
Wiring Regulations.
These tables are based on an ambient temperature of 30°C. This means that any
cables installed in an ambient temperature above this will need the correction factor
applying to them. This is because the cable will not be able to get rid of the heat it
gives off safely when carrying current.
When a cable runs through areas having different ambient temperatures, correction
factors should be applied to the highest temperature only.
The most common of the correction factors are given in the Tables 4B1 and 4B2
from BS7671 Correction factors for ambient temperature and are given in your
“Tables from BS7671 and the Onsite Guide”.
Complete the questions on the nest page to understand how ambient temperature
affects minimum cable ratings.

LEARNER WORK BOOK
Here you will see how ambient temperature can affect the selection of cable. The
perfect situation is 30°C therefore Ca = 1.0.
I n - term used to describe a circuit’s protection size

In in amps i.e. the fuse size.
Iz = I z - term used to describe a circuit’s value, in amps, once
all de-rating factors have been considered.
Ca C a – term for the correction factor of ambient temperature.
Using the table 4E4A and the Ca correction factors in your essential tables determine the
minimum size of XLPE cable for each of the circuits below. Make note of the cable insulation
type before you proceed with your calculations. You must write down:
In (fuse size), Ca (correction factor), Iz (de-rated CCC), cable size (mm²), It (tabulated CCC)
and your working out.
1. A single-line supply to a DB with a

design current of 50A and a MCCB
size of 100A, clipped direct at 30°C.
2. A single-line supply to a DB with a

design current of 50A and a MCCB
size of 100A clipped direct and ran
through a boiler house at 50°C.
3. A three line supply to a DB with BS88

fuses 50A and a maximum demand
of 45A, clipped direct and ran near to
hot machinery at 40°C
4. A three line supply to a DB with BS88

of 45A, clipped direct but re-routed to
30°C
In your own words how does ambient temperature affect the selection of cable? You may be
required to read you answer out to the class.

LEARNER WORK BOOK
Thermal Insulation - Ci
The use of thermal insulation in buildings, in the forms of cavity wall filling, roof space
blanketing, and so on, is now standard. Since the purpose of such materials is to limit
the transfer of heat, they will clearly affect the ability of a cable to dissipate the heat
build up within it when in contact with them. Thermal insulation has the effect of
wrapping a cable in a fur coat on a hot summer’s day. The heat produced when the
cable carries current cannot escape.
Loft insulation
The cable rating tables of the regulations as the one you have already used (Table
4E4A) allow for the reduced heat loss for a cable which is enclosed in an insulating
wall and is assumed to be in contact with the insulation on one side.
In all other cases, the cable should be fixed in a position where it is unlikely to be
completely covered by the insulation. Where this is not possible and a cable is buried
in thermal insulation for 0.5 m (500 mm) or more, a rating factor of 0.5 is applied.
This means that the current rating is halved or in other words the Iz value will be
doubled.
If a cable is totally surrounded by thermal insulation for only a short length (for
example, where a cable passes through an insulated wall), the heating effect on the
cable insulation will not be that significant. This is because heat will be conducted
away from the short high-temperature length through the cable conductor.
Clearly, the longer the length of cable enclosed in the insulation the greater will be
the de-rating effect. Table 52.2 (BS7671) shows the de-rating factors for lengths in
insulation of up to 400 mm and applies to cables having cross-sectional area up to 10
mm². Table 52.2 from BS7671 De-rating factors for cables up to 10mm² in cross-
sectional area buried in thermal insulation. Is given in your “Tables from BS7671
and the Onsite Guide”.
The Regulations use the symbol Ci to represent this correction factor.
Complete the questions on the next page to understand how thermal insulation
affects minimum cable ratings.

LEARNER WORK BOOK
Here you will see how thermal insulation can affect the selection of cable. The perfect
situation is no insulation therefore Ci = 1.0.

Ci C i – term for the correction factor of thermal insulation.
Using the table 4E4A and the Ci correction factors in your essential tables determine the
In (fuse size), Ci (correction factor), Iz (de-rated CCC), cable size (mm²), It (tabulated CCC) and
your working out.
1. A single-line supply to a load with a

design current of 13A and a MCB
size of 16A, reference method C with
no thermal insulation.
2. A single-line supply to a load with a

design current of 13A and a MCB
size of 16A, reference method C with
3000mm thermal insulation.
3. A three-line supply to a DB with BS88

of 27A, reference method E with
600mm of thermal insulation.
4. A three-line supply to a DB with BS88

of 27A, reference method E without
any thermal insulation.
In your own words how does thermal insulation affect the selection of cable? You may be
required to read you answer out to the class

LEARNER WORK BOOK
Grouping circuits - Cg
If a number of cables are installed together and each is carrying current, they will all
warm up. Those which are on the outside of the group will be able to transmit heat
outwards, but will be restricted in losing heat inwards towards other warm cables.
Cables 'buried' in others near the centre of the group may find it impossible to shed
heat at all, and will rise further in temperature.
Due to this, cables installed in groups with others (for example, if enclosed in a
conduit or trunking) are allowed to carry less current than similar cables clipped to, or
lying on, a solid surface that can dissipate heat more easily.
If surface mounted cables are touching the reduction in the current rating is, as would
be expected, greater than if they are separated. The picture below illustrates the
difficulty of dissipating heat in a group of cables.
Widely A closely packed

spaced cable cannot
cables easily dissipate
dissipate heat and so its
heat easily temperature
rises
The symbol Cg is used to represent the factor used for de-rating cables to allow for
grouping. Table 4C4 from BS7671 Correction factors for groups of more than
one circuit shows some of the most common values of Cg.
The grouping factors are based on the assumption that all cables in a group are
carrying rated current.
Note: If a cable is expected to carry no more than 30% of its grouped rated current, it
can be ignored when calculating the group-rating factor. For example, if there are
four circuits in a group but one will be carrying less than 30% of its grouped rating,
the group may be calculated on the basis of having only three circuits.
Complete the questions on the next page to understand how grouping affects
minimum cable ratings.

LEARNER WORK BOOK
Here you will see how grouping circuits can affect the selection of cable. The perfect
situation is no circuits grouped therefore Cg = 1.0.

Cg C g – term for the correction factor of grouping of circuits.
Using the table 4E4A and the Cg correction factors in your essential tables determine the
In (fuse size), Cg (correction factor), Iz (de-rated CCC), cable size (mm²), It (tabulated CCC)
and your working out.
1. A three-line supply to a socket with a

design current of 32A and a MCB size of
32A, reference method E not grouped.

design current of 32A and a MCB size of
32A, reference method E (touching) and
grouped with 7 circuits.
3. A single-line circuit with a 63A BS88

fuse protecting it, reference method E
grouped with one other circuit.
4. A single-line circuit with a 63A BS88

fuse protecting it, reference method E
and not grouped with any other circuit.
In your own words how does grouping circuits affect the selection of cable? You may be
required to read you answer out to the class

LEARNER WORK BOOK
Protection by BS3036 semi-enclosed (re-wireable) fuses - Cc
If the circuit concerned is protected by a BS3036 semi-enclosed (re-wireable) fuse

the cable size will need to be larger to allow for the fact that such fuses are not so
certain in operation as are cartridge fuses or circuit breakers. In other words, in the
event of a fault or an overload they will not disconnect as quickly as the other
protective devices available would do.
It has been known for a 5 amp BS3036 fuse to carry in excess of twice its rating
without any signs of operating!! Therefore the fuse rating must never be greater than
0.725 times the current carrying capacity of the lowest-rated conductor protected. In
effect, this is the same as applying a correction factor of 0.725 to all circuits protected
by semi-enclosed fuses.
Complete the questions below to understand how BS3036 fuses affect minimum
cable ratings.
I n - term used to describe a circuit’s protection size in

In amps i.e. the fuse size.
Iz = I z - term used to describe a circuit’s value, in amps, once all
de-rating factors have been considered.
Cc C c – term for the correction factor for the use of BS3036
fuses.
Using the table 4E4A in your essential tables determine the minimum size of XLPE cable for
each of the circuits below. You must write down your formulas. Note that this only applies to
circuits that use BS3036 fuses. You must write down:
In (fuse size), Iz (de-rated CCC), cable size (mm²), It (tabulated CCC) and your working out.

design current of 25A and a BS3036
size of 30A, reference method E.

design current of 25A and an MCB
size of 32A, reference method E.
3. A single-line circuit with a 60A

BS3036 fuse protecting it, reference
method C.
4. A single line circuit with an old 60A

BS88 fuse protecting it, reference
method C

LEARNER WORK BOOK
The effects of volt drop

What is volt drop?
All cables have resistance, and when current flows in them it results in a volt drop.
Hence, the voltage at the load is lower than the supply voltage by the amount of this
volt drop.
BS7671 states that the voltage at any load must never fall so low as to impair the
safe working of that load, or fall below the level indicated by the relevant British
Standard where one applies.
BS7671 also indicates that these requirements will be met if the voltage drop does
not exceed a certain % of the declared supply voltage. (See table 12A below).
Table 12A (BS 7671)

Maximum value of voltage drop
Lighting Other uses
(i) Low voltage installations
supplied directly from a
3% 5%
public low voltage
distribution system
(ii) Low voltage installation
supplied from a private LV 6% 8%
supply
Public supplies are those that are supplied by the local authority (from the National
Grid) where the consumer pays a bill for energy used. Private supplies are those
where the consumer generates their own electricity (E.g. An onsite power generation
plant such as a combined heating and power plant).
Public Supplies
For lighting
If the supply is single-line at the usual level of 230 V, this means a maximum
volt drop of 3% of 230 V, which is 6.9 V. This means the voltage at the load is as
low as 223.1 V. For a 400 V three-line system, allowable volt drop will be 12 V
with a line load voltage as low as 388 V.
For other uses (power, motors etc)

If the supply is single-line at the usual level of 230 V, this means a maximum
volt drop of 5% of 230 V, which is 11.5 V. This means the voltage at the load is
as low as 218.5 V. For a 400 V three-line system, allowable volt drop will be 20 V
with a line load voltage as low as 380 V.

LEARNER WORK BOOK
How to establish the value of volt drop
Each cable rating in the Tables of Appendix 4 of BS7671 has a

corresponding volt drop figure in milli-volts per ampere per metre of run
(mV/A/m). To calculate the cable volt drop
Ib × (mV / A / m )× L
Voltdrop =
1000
Where:
Ib = the design current in amps
mV/A/m = the milli volts per amp per metre dropped
L= the circuit length in metres
: 1000 = converts the millivolts into volts
Example
A 4 mm² p.v.c. sheathed circuit feeds a 6 kW shower and has a length of run of 16m.
Find the total voltage drop.
i) Work out the design current.

P 6000
I= = = 26.08 A
V 230
ii) Obtain the mV/A/m from Appendix 4
From Table 4D5A the volt drop figure for 4 mm² two-core cable is 11 mV/A/m.
iii) Input all the values into the formula and work out the volt drop to two
decimal places and add the value (V).
26.08 × 11× 16
Voltdrop = = 4.59v
1000
Since the permissible volt drop in this instance is 5% of 230 V, which is 11.5 V, the
cable in question meets volt drop requirements.

LEARNER WORK BOOK
Application of volt drop
It is important to appreciate that the allowable volt drop applies to the whole of an
installation from its source to the furthest point on the final circuit. If an installation
has mains, sub-mains and final circuits, for instance, the volt drop in each must be
calculated and added to give the total volt drop as indicated below.
Bigger cables Smaller cables
D D
D B LOAD
B B 3
2
1
1.5 volts 2.0 volts 4.4 volts
Overall voltage dropped = 7.9 V
Ways that too much volt-drop can affect equipment can be seen as follows.
While for a light bulb a large voltage drop will result in a harmless condition of slightly
less bright light being produced, incorrect voltages supplied onto delicate circuitry (as
for example in a DVD player, computer, and so forth) may quite easily result in an
electrically damaging condition. It is quite easy to have a circuit well within the
tabulated (I t) guidelines for its wiring, but whose voltage drop is too large.
For these reasons we are required to size wiring not only for the total current to be
drawn, but also to ensure that the total voltage drop shall not exceed the maximum
percentage (%). This is particularly the case when running long lengths of cable from
one end of a large building to another.
A consumer unit at 60 meters from a main distribution board to which is intended to

supply 30 amps should not necessarily be supplied with a 30 A cable. It may be
found that the resistance per metre of the cable is of such a value that the load
voltage would be below the required level.
Complete the questions on the next page to understand how voltage drop affects
minimum cable ratings.

LEARNER WORK BOOK
Using the tables in your “Tables from the regulations and On-site Guide” notes calculate the volt
drops of the various circuits below. Make note of the cable insulation type before you proceed
with your calculations. You must write down your formulas. You must record the table number,
show your calculations and state whether the cable passes or fails the voltage drop
requirement.
1. 20 metres of 1.5mm² cable supplying a

line line machine which carries 14
amps using Multi core 70°C armoured
thermoplastic (p.v.c) insulated cable
2. 4.0mm² three line supply, 40 metres in

length to a 32A socket used for
resistive loads only using Multi core
90°C armoured thermosetting (x.l.p.e)
insulated cables
3. A single line lighting circuit to supply 10

x 100w lamps with 60 metres of
1.0mm² using 70° thermoplastic (p.v.c)
insulated and sheathed flat cable with
protective conductor.
4. 80 metres of 1.5mm² cable for a 10KW,

three line load that has a power factor
of 0.90 using Multi core 90°C armoured
thermosetting (x.l.p.e) insulated cables
In your own words how does voltage drop affect the selection of cable? Look at the It values
and compare them with the Ib / In values. Analyse your findings. You may be required to read
you answer out to the class

LEARNER WORK BOOK
Shock protection
Protection against shock is a massively important factor to consider when designing
a circuit. A person in contact with a supply voltage for any length of time can be very
harmful, as we have previously seen. We as designers need to ensure that this
potential is limited to a very small amount of time by ensuring a faulty circuit
disconnects automatically.
Earth fault loop impedance and fault current
The path followed by fault current as the result of low impedance occurring between
the line conductor and earthed metal or circuit protective conductor is called the earth
fault loop. Fault current is driven through the loop impedance by the supply voltage.
The over-riding requirement is that sufficient fault current must flow in the event of an
earth fault to ensure that the protective device cuts off the supply before dangerous
shock can occur.
For normal 230 V TN systems, there are two different levels of maximum
disconnection time. These are:
• Any final circuit not exceeding 32A must disconnect within 0.4s
So any circuit rated at 32A or less must disconnect within 0.4 seconds.
• A distribution circuit or circuit exceeding 32A must disconnect
within 5s
A distribution circuit is a db supply or sub-mains feeder. So any
distribution circuit or circuit rated higher than 32A must disconnect
It must be appreciated that the longest disconnection times for protective devices,
leading to the longest shock times and the greatest danger, will be associated with
the lowest levels of fault current, and not, as is commonly believed, the highest
levels. Why is this?
Why are low levels of fault current more dangerous than higher levels?
Note that there is no such thing as a three-line line/earth fault, although it is possible
for three faults to occur on the three lines to earth simultaneously. As far as
calculations for fault current are concerned, the voltage to earth for standard UK
supplies is always 230 V, for both single-line and three-line systems. Thus the tables
of maximum earth-fault loop impedance, which are given in the appendices, apply
both to single- and to three-line systems.

LEARNER WORK BOOK
Earth Loop Impedance
Resistance (measured in ohms) is the property of a conductor to limit the flow of

current through it when a voltage is applied. The larger the conductor is the less
resistance it has. The smaller the conductor is the more resistance it has.
Thus, a voltage of one volt applied to one ohm resistance results in a current of one
ampere.
Refresh your memory with some Ohms law calcs.
1. A 230v supply is connected to a

resistance of 20 ohms. What is the
current?
2. A 230v supply with 3 amps of current

flows in a circuit. What is the
resistance?
3. A current of 12.5 amps flows through a

supply voltage?
4. A 230v supply is connected to a

current?
5. A 230v supply with 5 amps of current

flows in a circuit. What is the
resistance?
Q. Why is it called impedance when it clearly is just resistance?
A. It is termed impedance because part of the circuit is the transformer or

generator winding, which is inductive. This inductance, along with the
resistance of the cables to and from the fault, makes up the impedance.

LEARNER WORK BOOK
The earth fault loop path
The earth loop impedance we are concerned with is the worst-case scenario. This
means that we must ensure that the protective device will operate within the specified
disconnection time at the furthest point on the final circuit i.e. the furthest point on the
circuit from the protective device. This will then account for the highest impedance
path because each metre of cable has resistance and it will calculate the value at the
furthest length of the circuit’s conductors.
See the diagram below for the actual earth loop path of a fault.
1. The circuit
protective conductor
6. The line
conductor
supply from the
transformer to
the consumer
unit
7. The final
circuit live
conductor
5. The supply
transformer
winding
3. The suppliers
2. The main
return path,
earthing
either Faulty appliance –
conductor
combined, Live to earth fault
and the
separate or the
consumers
general mass of
earthing
earth
terminal
4. The earthed neutral of

the supply transformer
What value is acceptable?
A circuit is deemed to be “in compliance” if the value of earth loop impedance is

equal to or less then the maximum allowable for the device type and rating. Each
device type and rating has its own limits. Complete the questions on the next page to
become familiar with these limits and how they apply to a circuit.
So that we use the correct table to verify the calculated Zs value we need to know
the maximum disconnection time for the circuit being designed. Remember:
• Any circuit rated at 32A or less must disconnect within 0.4 seconds
• A distribution circuit or circuit exceeding 32A must disconnect within 5s

LEARNER WORK BOOK
Maximum values of earth loop impedance for various over-current protective devices
are shown in Table 41.2, 41.3 & Table 41.4 in your “Tables from the regulations and
On-site Guide”. Once the Zs has been established these tables are referred to
ensure the designed circuit is in compliance. Turn to these tables now to get familiar
with them.
What is the maximum Zs allowable for a 6 amp BS EN60898 Type D device?
Complete the following exercise to determine whether the Zs values of the circuits listed comply
with BS7671. You will need your “Tables from BS7671 and the on-site guide” appendices. You
must state the maximum disconnection time for the circuit; record the maximum Zs and the table
number; and state whether the cable passes or fails the shock protection requirement
1. A calculated value of earth loop

impedance (Zs) equating to 8.5 Ω for a
circuit supplying portable equipment.
With BS88 circuit protection rated at
6A.
2. A calculated Zs value of 1.2 Ω for a

With BS3036 circuit protection rated at
30A
3. A calculated calculated Zs value of 3.2

Ω for a circuit supplying fixed
equipment. With BS88 circuit protection
rated at 16A

circuit supplying fixed equipment. With
BS88 circuit protection rated at 100A

With BSEN60898 Type B circuit
protection rated at 6A

With BSEN60898 Type C circuit
protection rated at 6A

BSEN60898 Type D circuit protection
rated at 32A

BSEN60898 Type B circuit protection
rated at 40A
LEARNER WORK BOOK
How is earth loop impedance calculated?
Actual earth loop impedance can be calculated as follows:
Zs = Ze + (R1 + R 2 ) where (R1 + R 2 = Table ⋅ 9 A × L × Table ⋅ 9 B ⋅ or ⋅ 9C )

1000
Zs - term used to describe a circuit’s earth fault loop impedance, in ohms.
Ze - term used to describe part of the earth loop impedance that is external to the
installation.
R1 – term used to describe the impedance of the line conductor, in ohms found in Table 9A
R2 – term used to describe the impedance of the circuit protective conductor, in ohms
found in Table 9A
Length – length of circuit from supply to furthest point, in metres
Table 9B or 9C Multiplier – factor applied to allow for expected ambient temperature or
conductor resistance at maximum operating temperature respectively
Zs = Ze + (R1 + R2)
R1
Ze
R2
The actual Zs is the sum of all the impedances that are present in a circuit’s earth
fault path.
The Ze is something that we can either measure or obtain from our electricity
provider and is expressed in ohms. Typical maximum values are: TN-C-S (PME)
system 0.35 ohms, TN-S (cable sheath) 0.8 ohms, TT system 21 ohms
The R1 and R2 values are calculated in the following way. Table 9A from the On-site
guide lists the resistances in milli-ohms per metre of all sizes of cables up to 25mm².
Note that the values are in milli-ohms per metre. Table 9A values need to be
converted into ohms (by dividing by 1000) so you can add it to Ze.
Table 9B and 9C are multipliers that take into account the expected ambient
temperature at the time of test or maximum operating temperature of conductors.

LEARNER WORK BOOK
Multipliers are used by the designer and are required to allow for one of the
following:
Table 9B – Used so the designer can give values of resistance at the ambient
temperature expected during the tests (200C is classed as 1)
Table 9C – Used so the designer can give values of resistance at the conductor’s
maximum operating temperatures
Example
A circuit supplying a DB where a multi core armoured cable is clipped direct using 50
metres of multi core 25.0mm² 70°C armoured thermoplastic insulated cable. The
bunched CPC conductor size is 16.0mm². The Ze is 0.5Ω. Calculate the earth loop
impedance in Ohms at the maximum operating temperature.
i) Write down the formulas and obtain the values for each part.
Zs = Ze + (R1 + R 2 ) (R1 + R 2 = Table ⋅ 9 A × L × Table ⋅ 9 B ⋅ or ⋅ 9C )

1000
Ze = 0.5Ω; R1+R2 must be calculated; L = 50m
ii) Obtain the value for R1 and R2 in Ohms
Using Table 9A we can see that the resistance, in milli-ohms per metre, of 25.0mm²
and 16.0mm² is 1.877mΩ/m.
iii) Obtain the multiplier value from table 9C
The line and earth conductors are part of a thermoplastic multicore cable so are
classed as incorporated in a cable or bunched giving us a value of 1.20. Input all
values into the R1+R2 formula
1.877
R1 + R 2 = × 50 × 1.20 = 0.11Ω
1000
iv) Input the values into the main Zs formula and calculate Zs at the maximum
conductor operating temperature
Zs = 0.5 + 0.11 = 0.61Ω
Note: If the R1 and R2 value is measured this can be added to Ze to give the total Zs
Turn to Table 9A of your Tables from BS7671 and Onsite Guide and complete the
questions on the next page to gain some understanding of earth loop impedance
calculations.

LEARNER WORK BOOK
Complete the following exercise to determine the earth loop impedance (Zs) of the circuits.
Assume in all cases that the Ze = 0.3 Ω. You will need your “Tables from BS7671 and the on-
site guide” appendices. You must show all working out and state the R1 and R2 values and
show what Zs is for each circuit.
1. A circuit supplying a DB using

50 metres of multi core 70°C
armoured thermoplastic
insulated cable. The line and
earth conductors are both
25.0mm². What is the expected
Zs at the maximum operating
temperature?
2. A motor circuit where single

core conductors are installed in
p.v.c conduit using 40 metres of
90°C thermosetting single core.
The line and earth conductors
are both 4.0mm². What is the
expected Zs at the maximum
operating temperature?
3. A cooker circuit where 10m of

cable is installed in building
fabric using 70° thermoplastic
(p.v.c) insulated and sheathed
flat cable with protective
conductor. The line and earth
conductors are 6.0mm² and
4.0mm² respectively. What will
be the expected Zs at 10oC?
4. A power circuit where a 2.5

mm² cable is installed on a tray
using multi core 90°C armoured
thermosetting insulated cable.
The circuit length is 80 metres.
What will be the expected Zs at
5oC?

LEARNER WORK BOOK
Earth fault current
Once the Zs has been calculated we then calculate the earth fault current (If) using
the calculation below and then ensure that the device will disconnect within the given
time using the time / current trip curves in the tables from BS7671. If the time is less
than the maximum allowable for the circuit (i.e. At 230v, 0.4 or 5 seconds) we can be
sure that it will disconnect in time so that it provides protection from indirect contact.
We can also ensure that the protective device’s short circuit fault current capacity has
not been exceeded.
Uo
If =
Zs
I f - term used to describe a circuit’s earth fault current, in amps.
U o - term used to describe the nominal voltage to earth, in volts.
Z s – term used to describe the earth fault loop impedance, in ohms.
Example
A 230 V circuit is protected by a 15 A semi-enclosed (BS3036) fuse and has an
earth-fault loop impedance of 1.6 Ohms. What will be the maximum earth fault
current?
Uo 230
If = = = 143 .75 amps
Zs 1.6
This level of earth-fault current will cause the fuse to operate quickly. From the time /
current trip curves in BS7671, Fig 3.2A (more on these next) the time taken for the
fuse to operate will be about 0.15 s. Any load current in the circuit will be additional to
the fault current and will cause the fuse to operate slightly more quickly.
However, such load current must not be taken into account when deciding
disconnection time, because it is possible that the load may not be connected when
the fault occurs. Therefore if the earth loop impedance is higher this will restrict the
flow of fault current meaning the protective device will take longer to operate.
To gain some appreciation of fault current calculations complete the questions on the
next page.

LEARNER WORK BOOK
Complete the following exercise to determine the maximum earth fault current (If) of the circuits.
Assume in all cases that the Ze = 0.3 Ω. You must show all working out.
1. A circuit with a BS3036 overcurrent

protective device rating of 30A has
an R1+R2 value measured at 0.79
Ω.
2. A power circuit with a BS88

overcurrent protective device rating
of 32A has an R1+R2 value
measured at 0.56Ω.
3. A BS88 63A fuse protects a feed to

a three-line socket. The measured
R1+R2 value is 0.2 Ω.
4. A lighting circuit is protected by a

BSEN60898 – 10amp Type B
MCB. The measured R1+R2 value
is 1.5Ω.
5. A radial power circuit is protected

by a BSEN60898 – 32amp Type C
MCB. The measured R1+R2 value
is 0.8Ω.

LEARNER WORK BOOK
Time / current characteristics and disconnection times
In appendix 3 of BS7671 there are graph-like tables that represent the time / current
characteristics of the main types and rating of circuit protection. They are used to
determine the time it takes a device to operate under a certain amount of fault
current.
If you look at the time/current curve you will find that the scales on both the time
(seconds) scale and the prospective current (amperes) scale are logarithmic and the
value of each subdivision depends on the major division boundaries into which it
falls.
For example, on the current scale, all the subdivisions between 10 and 100 are in
quantities of 10, while the subdivisions between 100 and 1000 are in quantities of
100 and so on. This also occurs with the time scale, subdivisions between 0.01 and
0.1 being in hundredths and the subdivisions between 0.1 and 1 being in tenths, etc.
Remember:
• Any circuit rated at 32A or less must disconnect within 0.4 seconds
• A distribution circuit or circuit exceeding 32A must disconnect within 5s
If you look at Fig.3.2A in your “Tables from BS7671 and the on-site guide”
appendices you can see that current, in amps, is represented along the bottom (Χ-
axis) and along the side (Y axis) is the time in seconds.
Each line between two Three lines above the number 10

points represents a represents the value 40……
value in the lower of
the two units
Also available on each graph is a quick reference table that displays the main
disconnection times and the required amount of current to achieve those times.

LEARNER WORK BOOK
Example
Find out the expected disconnection time of a circuit that is protected by a 30A
BS3036 fuse when 70 amps of fault current flows.
i) Obtain the correct time/current graph for the selected protective device
from Appendix 3 of BS7671.
Look at Fig.3.2A. Find the 30amp BS3036 fuse trip characteristic line.
ii) Identify the fault current value on the Χ axis and follow it to the point
where it crosses the selected fuse rating curve.
Identify 70 amps on the Χ-axis. Follow 70 amps upwards until it crosses the 30amp
curve.
iii) At the point where the fault current crosses the fuse rating curve follow the
line across to the Y axis. Identify the value of time in seconds.
Follow the point where 70amps crosses the fuse line and track it (left) to the Y axis
and obtain the time. The disconnection time is expected to be 20 seconds.
Complete the exercise below using the “Tables from BS7671 and the on-site guide” appendices
to determine the operation times of different devices.
Over-current device and Prospective current Disconnection time

rating (Amps) (seconds)
BS3036 - 30 amp 100
BS3036 - 20 amp 70
BS88 – 32 amp 260
BS88 – 63 amp 450
BSEN60898 – 10amp 300

Type B
BSEN60898 – 32amp 300
Type C
BSEN60898 – 32amp 300
Type D
BS88 – 100 amp 400
BS88 – 6 amp 18
What if the disconnection time is

higher than the maximum allowed?
What can the designer do to ensure
that shock protection is afforded?
You should now have a good grasp of the way we determine the disconnection times
of a few devices based upon fault current levels.

LEARNER WORK BOOK
Thermal Constraints
Now that you have chosen the type and size of cable to suit the conditions of the
installation, we must look at ‘thermal constraints’. This is a check to make sure that
the size of the c.p.c, ‘the earth conductor’, complies with the IEE Wiring Regulations.
If there is a fault on the circuit, which could be a short circuit, or earth fault, a fault
current of hundreds or thousands of amperes could flow. Imagine that this is a 1 mm²
or 2.5 mm² cable; if this large amount of current was allowed to flow for a short period
of time, i.e. a few seconds, the cable would melt and a fire would start. The c.s.a of
the circuit protective conductor (c.p.c) is of great importance since the level of
possible shock in the event of a fault depends on it.
We need to check that the c.p.c will be large enough to be able to carry this
fault current without causing any heat/fire damage. The formula that is used
to check this situation is the adiabatic equation. The c.p.c will only need to
carry the fault current for a short period of time, until the protective device
operates.
The cable calculation process at this point has ensured the selected cable will safely
carry the design current and will disconnect in the required time therefore protecting
the circuit from danger. The final stage of the calculation process is to confirm that
the circuit protective conductor can withstand the fault current for a short space of
time, for example 0.4 or 5 seconds at 230 volts.
In very many cases, calculation of the CPC size will show that a smaller size than
that detailed in is perfectly adequate. The adiabatic equation is:
I 2 ×t
S=
k
S - term used to describe the c.s.a of the circuit protective conductor, in
mm².
I - term used to describe the earth fault current, in amps.
t – term used to describe the time earth fault current will be present in the
circuit, in seconds.
k – term used to describe the factor which takes into account the
resistivity, temperature coefficient and heat capacity of the conductor
material, and the appropriate initial and final temperatures. (See tables
54.1 to 54.6)
By using Ohms law the earth loop impedance value and the supply voltage
are used to calculate how much fault current (I) will flow.
The disconnection time of protective device is determined by using the fault
current value and the correct time/current curve table from Appendix 3 of
BS7671.
K is determined by assessing what the CPC material is and how it is installed
in relation to the line conductors.

LEARNER WORK BOOK
Example
Find out the minimum size of c.p.c in mm² so that the 50A BS88 circuit complies with
BS7671. The protective conductor is a copper conductor incorporated in a 90°C
Thermosetting conductor cable. The calculated fault current is 300 amps.
I2 ×t
S=
k
i) Obtain all values for the adiabatic equation.
I is either worked out as shown previously or declared
t-is established using the graphs in Appendix 3 of BS7671
k- is established using the tables from Section 5 of BS7671
I is 300amps; t is 1 second (fig.3.3A); k is 100 (table 54.3)
ii) Work out I² x t first; then square root; then divide by the k value
300 2 × 1
S= = 3mm 2
100
The minimum size of c.p.c. is 3 mm². If the actual selected cable is more than this
then thermal constraints have been satisfied. If the c.p.c is smaller than this it will not
handle the fault current safely.
If S is smaller than the selected cpc size, what will we need to do so that the cable complies
with thermal constraints?
Safety could always be assured if we assessed the size using Table 54.7 as a basis.
However, this could result in a more expensive installation than necessary because
we would often use protective conductors which are larger than those found to be
acceptable by calculation
So you can gain some more understanding complete the exercise on the next page
to calculate the minimum size of C.P.Cs. You will need your “Tables from BS7671
and the on-site guide” appendices.

LEARNER WORK BOOK
Minimum size of c.p.c

Complete the following exercise to determine the minimum size of CPC for the circuits using the
adiabatic equation. You must show all working out; state the calculated size of CPC and the
actual size to be installed.
1. The protective conductor

installation is steel armour inside a
70°C Thermoplastic (PVC) cable
with an 80A BS88 has a calculated
fault current of 500 amps.
2. A fault current of 1000A is

calculated on a circuit with a 100A
BS88 fuse where the CPC is 70°C
Thermoplastic (PVC) not bunched
with cables

installation is steel armour inside
90°C Thermosetting conductor
incorporated in a cable with a 32A
BSEN 60898 Type B has a
calculated fault current of 300
amps.
4. A fault current of 150A is calculated

on a circuit with a 30A BS3036 fuse
where the CPC is 70°C
Thermoplastic (PVC) bunched with
cables

installation is Steel conduit
containing 70°C Thermoplastic
(PVC) with a 32A BSEN 60898
Type C has a calculated fault
current of 250 amps.
There is a problem with question 5. Can you see what it is Look at the values in the formula?
Once you discover it explain what will have to be done.
Once the cable calculation process has reached this stage the entire process is complete
and the requirements of BS7671 have been met

LEARNER WORK BOOK
Now complete the questions below
1. Write down the formula to establish the total design current I b of in two types of
circuit.
2. What is I n and how is it established?
3. What four correction factors need to be taken into account when calculating the
minimum size of a circuit conductor? Write down their symbols and descriptions
4. Once all these factors have been taken into consideration and we obtain I z what
needs to be established next and what do we use to achieve it?
5. Once the circuit conductor has been selected we need to ensure that is complies with
volt drop? Write down the formula and explain its parts.
6. Explain what shock protection is and state how we ensure it is adhered to. Write
down the formula
7. Explain what thermal constraints are and state how we ensure it is adhered to. Write
down the formula.

LEARNER WORK BOOK
Full cable calculation
Now complete a cable calculation and decide what cable size should be installed
based upon a complete installation decided by the group. Make sure you consider all
factors before you begin and write them in the boxes below. Then use the space
below to carry out the calculations.
Load details Cable Type Installation details

Type:
Rating:
Voltage:
Supply details Circuit details

DB type: Length of run:
Ze value Correction factors:

LEARNER WORK BOOK
This page is for you the continuation of your calculation Cable calculation process
1. Work out the design current Ib
Using a the correct formula
P
I=
V
2. Select the protective device size
Ib ≤ In
3. Obtain all correction factors

Find the values so they can be used in
the next calcualion
Ca, Cc, Cg, Ci
4. Calculate Iz
In divided by all factors
In
Iz =
Ca × Ci × Cg × Cc
5. Select conductor sizes
With Iz use the tables in Appendix 4 and
choose.
Iz ≤ It
6. Calculate volt drop

Use design current, mV/A/m value from
cable table, the circuit length then ÷1000
Ib × (mV / A / m )× L
Voltdrop =
1000
7. Calculate R1+R2
Using table 9A, 9B and 9C find the mΩ/m
value ÷ 1000 then apply multipliers
9A
R1 + R 2 = × 9 B × 9C = Ω
1000
8. Calculate Zs
Zs = Ze + R1 + R 2 = Ω
9. Verify Zs value with BS7671
Using the tables in Section 41 ensure
calculated value is less than the
tabulated value to ensure shock
protection
10. Calculate the fault current

Using nominal voltage and Zs
Uo
I= =A
Zs
11. Establish the disconnection time
Using the fault current, device type and
time / current graphs in Appendix 3
obtain the expected disconnection time
12. Calculate minimum size of CPC

Using the adiabatic formula, input all
values (including k factor) and work out
min. size of cpc. Then compare with our
chosen cpc size
I2 ×t
S=
k
13. Once all above has been verified the
process is complete

LEARNER WORK BOOK
Cable capacities of conduit and trunking

Not only must it be possible to draw cables into completed conduit and trunking
systems, but also neither the cables nor their enclosures must be damaged in the
process. If too many cables are packed into the space available, there will be a
greater increase in temperature during operation than if they were given more space.
It is important to appreciate that grouping factors still apply to cables enclosed in
conduit or trunking.
Cables in conduit
Conduit Capacities
To calculate the number of cables that may be drawn into a conduit, we make use of
four tables below. These have been adapted from the on-site guide to show the two
most common conduit sizes used today. The conduit terms are shown in your
“Tables from BS7671 and the Onsite Guide”.
Table 5A (Onsite guide) - Cable factors for conduit in short straight runs up to 3m
Table 5B (Onsite guide) - Conduit factors for use in short straight runs up to 3m
Table 5C (Onsite guide) - Cable factors for long straight runs over 3m, or runs of
any length incorporating bends.
Table 5D (Onsite guide) - Conduit factors for conduit incorporating bends and
long straight runs
The number of cables that can be drawn into or laid in any enclosure of a wiring
system must be such that no damage can occur to the cables or the enclosure during
installation. The number of cables that can be used is the overall sum of the cables
cross-sectional area (c.s.a) compared to the overall c.s.a of the trunking. This is
expressed as a percentage and should not exceed 45 per cent.
To calculate the required size of conduit we must first establish the amount of
conductors to be installed. We must then obtain the individual terms for individual
conductors and multiply them together. If we have 5 cables of one size we multiply
the term for that cable by 5. We treat each size of conductor as an individual sum.
Once we have obtained all the calculated terms we add them all together to give one
total. We then refer to the relevant table and discover which conduit term is
compatible. Bear in mind that the conduit term shown is the upper limit of spacing
and should not be exceeded under any circumstances.

LEARNER WORK BOOK
Complete the following conduit sizing exercise using the four tables listed above. You must
record the cable factors, show your calculations and select the correct size conduit. All cables
are stranded. See if you can make a guess before you calculate the answers.
E.g Conduit 2.5 metres long without bends with 3 x 1.5mm² and 3 x 2.5mm² stranded
conductors
i) Select the correct table for the cable factors and conduit (5A)
ii) Obtain the cable factors for each size of cable (1.5mm² =31 and 2.5mm² =43)
iii) Multiply the number of cables by the factors (3x31)+(3x43)=222
iv) Select the correct table for the conduit factors and length of run (5B)
v) Obtain the factor which is greater than the sum of cable factors (20mm=420)
vi) The conduit size is 20mm
1. Conduit 2.5 metres long without bends

with 6 x 1.5mm² and 6 x 2.5mm²
2. Conduit 3.5 metres long without bends

with 5 x 6.0mm²
3. Conduit 6.0 metres long with one bend

with 5 x 1.5mm² and 3 x 4.0mm²
4. Conduit 2.0 metres long with two

bends with 3 x 16.0 mm²
5. Conduit 10 metres long one bend with

6 x 1.5mm² and 6 x 2.5mm²
6. Conduit 3 metres long three bends with

5 x 6.0mm²
7. Conduit 8.0 metres long with two

bends with 5 x 1.5mm² and 1 x 4.0mm²
8. Conduit 2.0 metres long with one bend

with one ring main and a single line 6.0
mm² cooker supply

LEARNER WORK BOOK
Trunking capacities
Minimum trunking size is calculated in much the same way as conduit although
trunking has its own table of terms for single core cable. No consideration though, is
paid to the length of run.
The sizes should ensure an easy pull, with low risk

of damage to cables and enclosures. The electrical
effects of grouping are not taken into account.
Therefore, as the number of circuits increases, the
current-carrying capacity of the cables will
decrease. Cable sizes would have to be increased
with a consequent increase in cost of cable and
trunking. It may therefore be more economical to
100x100
divide the circuits concerned between two or more
enclosures.
The tables show the factors for trunking having taken into consideration the
maximum allowable 45% space factor. Sizes in bold are the most common trunking
sizes available.
The trunking terms are shown in your “Tables from BS7671 and the Onsite Guide”.
Table 5E (Onsite guide) - Cable factors for trunking

Table 5F (Onsite guide) - Factors for trunking
E.g. Trunking with 100 x 1.5mm² and 100 x 2.5mm²

i) Obtain the cable factors for each size and type of cable (1.5mm² =8.6 and
2.5mm² =12.6)
ii) Multiply the number of cables by the factors (100x8.6)+(100x12.6)=2120
iii) Obtain the factor which is greater than the sum of cable factors (75x75=2371)
iv) The trunking size is 75mmx75mm

LEARNER WORK BOOK
Complete the following trunking sizing exercise using the two tables above. You must record the
cable factors, show your calculations and select the correct size trunking. All cables are
stranded to BS6004.
1. A trunking installation with

6 x 1.5mm²,
6 x 2.5mm²,
3 x 4.0mm² and
3 x 6.0mm² conductors.

12 x 1.5mm²,
12 x 2.5mm²,
9 x 4.0mm², 3 x 6.0mm² ,
3 x 10.0mm² , 1 x 16.0mm² and

18 x 1.5mm², 24 x 2.5mm²,
12 x 4.0mm², 20 x 6.0mm² ,
12 x 10.0mm² , 20 x 16.0mm² and

10 single-line lighting circuits,
10 ring mains,
8 x A2 radial circuits (32A),
10 x 6.0mm² SP&N circuits,
5 x 10.0mm² TP&N circuits,
8 x 16.0mm² TP&N circuits,
5 x TP&N DB supplies with 25.0mm²
conductors
1 x 25mm² earthing conductor and
6 x 16.0mm² Main equipotential
bonding conductors

LEARNER WORK BOOK
Maximum demand and diversity

In this section we will look at Maximum Demand and Diversity. The current demand
for a final circuit is determined by adding up the current demands of all points of
utilisation and equipment in the circuit and, where appropriate, making an allowance
for diversity.
Typical demands to be used for this summation are given in Table 1A of the
On-Site Guide.
In most cases main or sub-main cables will supply a number and/or variety of final
circuits. Use of the various loads must now be considered, otherwise if all the loads
are totalled, a larger cable than necessary will be selected at considerable extra cost.
Therefore a method of assessing the load must be used. This method is called
“applying diversity”.
Maximum Demand
Maximum demand is the largest current normally carried by circuits, switches and
protective devices under normal operating conditions. Assessment of maximum
demand is sometimes straightforward. For example, the maximum demand of a 230V
single-line 8 kW shower heater can be calculated by dividing the power (8 kW) by the
voltage (230 V) to give a current of 34.78 A.
There are times, however, when assessment of maximum demand is less obvious.
For example, if a ring circuit with 15 x 13A sockets, the maximum demand clearly
should not be 195A (15 x 13A). Some 13A sockets may feed table lamps with 60 W
lamps fitted, whilst others may feed 3 kW washing machines; others again may not
be loaded at all.
Lighting circuits pose a special problem when determining maximum demand. Each
lamp-holder must be assumed to carry the current of 0.43A per lamp (100 W per
lamp holder). Discharge lamps are particularly difficult to assess, and current cannot
be calculated simply by dividing lamp power by supply voltage. We have to multiply
the total lamp power by 1.8 to allow for some losses. The reasons for this are:
Control gear losses result in additional current,

The power factor is usually less than unity so current is greater
When assessing maximum demand, account must he taken of the possible growth in
demand during the life of the installation. As a rule of thumb this is generally 20%.
The maximum demand is the “expected” current that a circuit will carry.
When calculating the maximum demand of an installation of three ring mains what do you
expect the value of current to be? Explain the reasoning behind your answer

LEARNER WORK BOOK
Diversity
Diversity is defined as making a realistic estimate as to how much the maximum

demand will be under an installation’s normal operating conditions.
Appendix 1, Table 1B, of the IEE On-Site Guide contains the recommended diversity
allowances, which allows diversity to be applied depending upon the type of load and
installation premises.
The individual circuit / load figures are added together to determine the total
‘Assumed Current Demand’ for the installation. This value can then be used as the
starting point to determine the rating of a suitable protective device and the size of
cable, considering any influencing factors in a similar manner to that applied to final
circuits.
Please remember that the calculation of maximum demand is not an exact

science and a suitably qualified electrical engineer may use other methods
of calculating maximum demand.
A domestic ring circuit feeds a large number of 13A sockets and is protected by a
32A fuse. If all sockets were feeding 13A loads, more than two of them in use at the
same time would overload the circuit and its protective device would disconnect it.
In practice, the chance of all domestic ring sockets feeding loads taking 13 A is small.
Most sockets feed small loads such as table lamps, vacuum cleaner, television or
audio machines and so on. The chances of all the sockets being used simultaneously
are remote. The consideration that only a few sockets will be in use at the same time
is called “diversity”.
By making allowance diversity, the number of circuits and their rating can
be reduced, with a consequential financial saving. However, if diversity is
over-estimated, the normal current demands will exceed the ratings of the
protective devices, which will disconnect the circuits. Overheating may
also result from overloading which exceeds the rating of the protective
devices.
The sensible application of diversity to the design of an installation calls for

experience and a detailed knowledge of the intended use of the installation. Future
possible increase in load should also be taken into account. Diversity relies on a
number of factors that can only be properly assessed by having a detailed knowledge
of the type of installation and the habits and practices of the users. Not knowing how
an installation is to be used could mean that installation conductors and equipment is
under or over-rated
We will now take a look at how diversity is implemented.

LEARNER WORK BOOK
Point of utilization or current using Current demand to be assumed

equipment
2 amp sockets At least 0.5A
Lighting outlet Connected load, minimum 100 W
Shaver outlet, bell transformer or any May be neglected
equipment rated 5 watts of less
Household cooking appliance The first 10 A of the rated current plus
30% of the remainder plus 5A if the
control unit incorporates a socket
All other stationary equipment Rated current
Table 1A – On site guide
Current Demand to be assumed for points of utilization and current using
equipment
Note 1 See Table 1B in your Tables from BS7671 and Onsite Guide for the design of
other socket outlets.
Note 2 Final circuits for discharge lighting take into to account harmonic currents and
control gear losses. Where the exact manufacturer’s information for gear losses is
not available the maximum demand shall be assumed to be 1.8 x the lamp rating.
Work out the following current demands with and without diversity using table 1A above. Then in
pairs discuss the implications of diversity both when done correctly and incorrectly.
Current using Number of Maximum Maximum demand with

equipment points / demand without diversity
Rating diversity
2A sockets 20
Lighting outlet 12 x 100 watts

each
Household 6kW with

cooker socket on main
switch
Apart from indicating that diversity and maximum demand must be assessed, the
Regulations themselves give little help. Suggestions of values for the allowances for
diversity are given in Table 1B in your Tables from BS7671 and Onsite Guide.

LEARNER WORK BOOK
Example diversity calculation

We will now take a look at diversity on a larger scale by considering the example
below.
A shop has the following single-line loads, which are balanced as evenly as possible
across the 400 V three-line supply.
Example – Small Shop
1. 2 x 6 kW and 7 x 3kw thermostatically controlled water heaters

2. 2 x 3 kW instantaneous water heaters
3. 2 x 6 kW and 1 x 4 kW cookers
4. 12 kW of discharge lighting (Sum of tube ratings)
5. 8 x 32 A ring circuits feeding 13 A sockets.
Q. Calculate the total demand of the system, assuming that diversity can be applied.
Calculations will be based on Table 1B. The single-line voltage for a 400V three-line
system is 400 / √3 = 230 V.
All loads with the exception of the discharge lighting can be assumed to be at unity
power factor, so current may be calculated from:
Where: I = the design current in amps

P P = the circuit power in watts
I= V = the circuit voltage in volts
V
1. Water heaters (thermostatic) 2 x 6 kW and 7 x 3kw
Table 1B states “No diversity is allowable”, so the total load will be:
P = (2 × 6 ) + (7 × 3)kW = 12 + 21 = 33kW
33,000
I= = 143 .47 A
230
2. Water heaters (instantaneous) 2 x 3 kW
Table 1B states “100% of the largest and 100% of 2nd largest.” So the total load will
be:
P = 2 × 3 = 6 kW
6000
I= = 26.08 A
230

LEARNER WORK BOOK
3. Cookers 2 x 6 kW and 1 x 4 kW
Table 1B states “100% of the largest and 80% of 2nd largest. 60% of remainder” So
the total load will be:
First cooker 6000

I= = 26 .08 A
230
6000 80
Second cooker I= = 26.08 A × = 20.86 A
230 100
4000 60
Third cooker I= = 17.39 A × = 10.43 A
230 100
Total for Cookers =57.37A
4. Discharge lighting 12 kW
Table 1B states “90% of total current demand” So the total load will be:
12000 × 1.8 90
I= = 93 .91 A × = 84.52 A
230 100
5. Ring circuits 8 x 32 A
Table 1B states “100% of the largest and 50% of remainder” So the total load will be:
First ring main I = 32 A

50
Remaining Ring mains I = 7 × 32 = 224 A × = 112 A
100
Total for Ring mains =144A

LEARNER WORK BOOK
Total current demand after diversity is applied.
Thermostatically controlled water heaters = 143.47 A

Instantaneous water heaters = 26.08 A
Cookers = 57.37 A
Discharge lighting = 84.52 A
Ring circuits feeding 13A sockets = 144 A
TOTAL = 455.44 A
455 .44
Then we divide by three to balance across three lines = 151 .81 A
3
Therefore the switchgear we select can be rated to take 151.81 amps. In

this instance we would select the next largest size of switchgear, which is
160 Amps.
If diversity hadn’t been applied explain what would happen to the maximum demand and state
the implications?

LEARNER WORK BOOK
Now answer the question on diversity below
A small hotel has the following single-line loads, which are balanced as evenly as
possible across the 400 V three-line supply.
EXAMPLE - SMALL HOTEL
a. 10 kW of discharge lighting (Sum of tube ratings)

b. 6 kW of low voltage lighting (cos Φ = 0.95)
c. 5 x 3kW thermostatically controlled water heaters
d. 2 x 3 kW instantaneous water heaters
e. 5 x 8.5 kW shower units
f. 3 x 6 kW and 1 x 3 kW cookers
g. 6 x 32A ring circuits feeding 13A sockets.
h. 1 x 8 kW Under-floor heating
Calculate the total demand of the installation, assuming that diversity can be applied and work
out the approximate balanced load across three lines. Calculations will be based on Table 1B.
Use this and the next page for your working out.

LEARNER WORK BOOK
This page has been left intentionally blank

LEARNER WORK BOOK
Now complete the questions below.
1. What is another name for the current that flows in a circuit?
2. Explain what maximum demand is.
3. Write down the formula for working out the current for a single-line discharge lighting
circuit.
4. Explain what diversity is and how it is used with the maximum demand of a circuit.
5. Explain why it is sometimes necessary to ensure diversity is applied.
6. Why is it important to have a good understanding of an installation when making

allowances for diversity?

Sizing Cables, Conduit and Trunking

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Sizing Cables, Conduit

Sizing Cables Conduit and Trunking REV4.1 2

Sizing Cables, Conduit and Trunking Unit Overview..................................6

The price of cable ..........................................................................................7

Cable calculation process.............................................................................8

The effects of volt drop ...............................................................................23

Thermal Constraints ....................................................................................38

Cable capacities of conduit and trunking ..................................................44

Maximum demand and diversity.................................................................48

Sizing Cables Conduit and Trunking REV4.1 3

As we have already discovered previously copper is a very good electrical conductor.

Al and Cu Comparison for 500A cable

Sizing Cables Conduit and Trunking REV4.1 4

This workbook is to be accompanied by PowerPoint

Sizing Cables Conduit and Trunking REV4.1 5

Sizing Cables, Conduit and Trunking Unit Overview

How to select a suitably sized cable including:

Sizing Cables Conduit and Trunking REV4.1 6

The price of cable

4 core 1.5mm² XLPE / SWA 1.11 93.99

Complete the following exercise.

1. 50M of 4 core 1.5mm² XLPE / SWA in one coil

2. 200M of 4 core 1.5mm² XLPE / SWA in two coils

3. 100M of 4 core 16.0mm² XLPE / SWA in five coils

4. 100M of 4 core 16.0mm² XLPE / SWA in one coil

Sizing Cables Conduit and Trunking REV4.1 7

Cable calculation process

External influences Application of correction factors

Sizing Cables Conduit and Trunking REV4.1 8

Where: I = the design current in amps (A)

Inductive and / or capacitive loads

Sizing Cables Conduit and Trunking REV4.1 9

i) Select the correct formula. (Single line; 230v, resistive)

i) Select the correct formula. (Three line; 400v, inductive)

Sizing Cables Conduit and Trunking REV4.1 10

Over-Current Protective Device – I n

1 Amount of Overload current

2 Amount of Fault current

The temperature of two conductors at the point of a fault can be as high as

Sizing Cables Conduit and Trunking REV4.1 11

Fuse sizes of BS88 over-current protective devices (Amps)

6 10 16 20 25 32 40 50 63 80 100 125 160 200

1. A single line, resistive lighting circuit

2. A single line heating circuit with a total

3. A single line, inductive lighting circuit

4. A three line heating system with a total

5. A single-line supply to a 100A

Sizing Cables Conduit and Trunking REV4.1 12

1. A 4.0mm², two core cable, carrying alternating

2. A 10.0mm², four core cable, carrying A.C current

3. A 16.0mm², single line cable supplying a

4. A 25.0mm², three line and neutral supply for an

5. A 25.0mm², three line and neutral (TP&N)

Sizing Cables Conduit and Trunking REV4.1 13

Sizing Cables Conduit and Trunking REV4.1 14

What If More Than One Factors Are Present?

Ca=0.91; Ci=n/a; Cg=n/a; Cc=n/a

Sizing Cables Conduit and Trunking REV4.1 15

This is the temperature of the surroundings of

Sizing Cables Conduit and Trunking REV4.1 16

I n - term used to describe a circuit’s protection size

1. A single-line supply to a DB with a

2. A single-line supply to a DB with a