sy, 1:21 AM Howto select cable size for various loads wih calculation wth rea fe expos? How to select cable size for various loads with calculation with real life examples? By Bharat Ribaciya « June 07, 2017 Voltage drop in Cables Voltage drop is a important factor to consider while selecting cable size. Every cable have internal resistance and this resistance is directly proportional to it's length and inversely proportional to it's diameter[R = p (L/a)]. It can be neglect in small diameter and small length wire but it must have to consider in long cable or big diameter cable. As per standard voltage drop between power supply terminal and installation not be increase above 2.5% of supply voltage. i.e. If supply voltage is 220 V then voltage drop not be increase then the 5.5 V. Voltage drop also occur in between installation point(distribution box) & sub-circuit or final sub-circuits and this drop should be half of that allowable voltage drop. i.e. 2.75 V of 5.5 V. Their are two method to describe voltage drop, The Si(System International and Metric System) and FPS(Foot Pound System). In SI system voltage drop describe in A/m and in FPS system it describe as 100 feet. Tables for Suitable Cable & Wire Sizes For proper size of cable or wire the selection tables are given below: Current No. ofwire | Area Current No.of wire Area carying andthickness. (Inmm?) — carrying andthickness__(Inmm*) capacity of each wire capacity of each wire (In Amp) (in Amp) a 11.13 1 a 1/0.044 0.0015 13 11.38 15 13 3/0.029 0.002 18 W/1,78 25 16 3/0.036 0,003 24 710.85 4 2 7/0.029 0.0045 31 7/104 6 28 710.036 0.007 42 WN.35 10 34 710.044, 0.01 56 INTO 16 43 7/0.052 0.0145 73 W214 25 56 7/0.064 0.0225 hpsielecrical20a blogspot car/2017/0/suitaee-cable-sizo Hindsy, 1:21 AM Howto select cable size for various loads wih calculation wth rea life exarples? 90 19/1.53 35 66 19/0.044 0.03 145 19/1.78 50 77 19/0.052 0.04 185 19/2.14 70 105 19/0.064 0.06 230 19/2.52 95 180 19/0.83 04 Table 1 - Current rating of Cu cables at 30°C or 86F Current No. of wire Area Current No. of wire Area carrying and (inmm) carrying and (mm) capacity thickness of capacity thickness of (inamp) each wire (inamp) each wire 3 16/0.20 Os 3 14/0.0076 0.0006 6 24/0.20 0.75 6 23/0.0076 0.001 10 32/0.20 1 13 40/0.0076 0.00017 13 40/0.20 1.25 18 70/0.0076 0.003 15 48/0.20 15 24 110/0.0076 0.004 20 80/0.20 25 31 162/0.0076 0.007 Table 2 - Current rating of flexible cords Cu cables at 30°C or 86F Temp 1.02 1 097 | 094 | O91 088 | 077 | 0.63 Factor TempF 77 86 95 104 113 122 1131 140 Temp*C 25 30 35 40 45 50 55 60 TempK 298.15 303.15 308.15 313.15 318.15 323.15 328.15 333.15 ‘Table 3 - Temperature factor Inside Trunking & Conduit Conductor Single phase one cable AC & | Three phase three or four No. & Cross oc core cable Diameter of | Section Area wires (In (in inch?) Inch) Current. Volt Current Volt Rating (A) Drop/100 Rating (A) Drop/100 Feet (V) Feet (V) i 14 9 9.8 1/0.044 0.0015 13 12 al 91 3/0.029 0.002 16 m1 14 77. 3/0.036 0.003 2 84 18 6.4 7/0.029 0.0045 28 7 23 5.3 7/0.036 0.007 34 57 28 Al 7/0.044 0.01 43 5.5 36 4 7/0.052, 0.0145 56 48 48 3.5 710.064 0.0225 66 43 56 32 71970.044 0.03 77 36 65 27 19/0.052 0.04 105 34 88 25 19/0.064 0.06. Table 4- Cable size, Current ratings with Voltage drop (British System) hpsielecrcal20a blogspot car/2017/0/suitate-cable-sizo Hind 29sy, 1:21 AM Howto select cable size for various loads wih calculation wth rea fe expos? Inside Trunking & Conduit Conductor Single phase one cable AC & | Three phase three or four No. & Cross oc core cable Diameter of | Section Area (in mm?) wires (In mm) Current Volt Current Volt Rating (A) | Drop/Amp- | Rating(A) | Drop/Amp- meter(mVolt meter(mVolt ) ) ii 41 9 35, 1/1.13 1 13 28 12, 24 1/1.38, 1.5 18 7 16 15 1/1.78 25 24 ii 22 91 7/0.85 4 31 7 27 6 7/104 6 40 Al 37 3.6 7/135 10 53 26 a7 22 77.10 16 60 V7 53 1.5 F214 25 74 1.2 65 1 19/1.53 35 Table 5 - Cable size, Current ratings with Voltage drop (SI/Decimal/Metric System) ‘Steps to find out voltage drop ina cable Step 1-Find the maximum allowable voltage drop. Step 2Find load current and according to load current, select a proper cable from table (which current rating nearest to the load current). ‘Step 3-Find the voltage drop in meter or 100feet according it's rated current from table 1 Step 4-Calculate the voltage drop for the actual length of wiring circuit according to it’s rated current by using these formulas. Voltage drop (In per meter) = (Actual length of circuit * voltage drop for 1m) /100 Voltage drop (In 100feet) = (Actual length of circuit * volt drop for 100ft) /100 ‘Step Now, find out voltage drop by using load factor Load factor = Load current of cable/ Rated current of cable Find out the rated current of cable from table and this value of load factor is voltage drop in the cables when the current is passing through it. If this value of voltage drop is less then the maximum allowable voltage drop which calculated in step 1, then the selected size of cable is hipsielectrcal24x Hog spe cr/2017/0/eittle-cable-sizelind 39sv, 1:21 AM Howto sleet able size for srcs load wth clean wh el fe antes? proper but if it is greater then the step 1 max. allowable voltage drop then calculate the voltage drop greater size until it value becomes less then the step 1 voltage drop. Examples - Find out proper cable size for given load To determine cable size keep in mind these rules of voltage drop. + For a given load, there should be 20% extra scope of current for additional, emergency or future needs (except the known value of current). ‘+ From Energy meter to DB, voltage drop should be 1.25% and 2.5% for final sub-circuit should not exceed 2.5% of Supply voltage. ‘+ Use temperature factor for considering change in temperature from table 3 and consider load factor while finding cable size. + Selecting cable size consider the wiring system (Temperature is low in open wiring system then the conduit wiring) + Consider diversity factor in wiring installation ‘Solved examples for cable size selection Example 1 - For Electrical wiring installation in a building, Total load is 4.5kW and total length of cable from energy meter to sub circuit distribution board is 35 feet. Supply voltages are 220V and temperature is 40°C (104°F). Find the most suitable size of cable from energy meter to sub circuit if wiring is installed in conduits. Solutior-(British System) Total Load = 4.5 kW = 4.5 x 1000 W = 4500 W and 20% additional loa w =Total Load = 4500 W + 900 W = 5400 W 4500 x (20/100) Total Current = | = P/V = 5400 W /220 V =24.5.A For the load current the size of cable is 7/0.036(28 A) from table. Now, check the temperature factor from table 3, it is 0.94 at 40°C and current carrying capacity of cable size 7/0.036 is 28 A. So, Current rating for 40°C = 28 x 0.94 = 26.32. A It is less then the current carrying capacity of selected cable which is 28 A, therefore it is also suitable with respect to temperature. hpsielecrical20a blogspot car/2017/0/suilate.cable-sizo Hindsy, 1:21 AM Howto select cable size for various loads wih calculation wth rea fe earrples? Now find the voltage drop for 100 feet for this (7/0.036) cable from Table 4 which is 7 V, But in our case, the length of cable is 35 feet. Therefore, the voltage drop for 35 feet cable would be; Actual Voltage drop for 35 feet = (7 x 35/100) x (24.5/28) = 21 V And Allowable voltage drop = (2.5 x 220)/100 = 5.5 V Here, The actual voltage drop (2.1 V) is less than that of maximum allowable voltage drop of 5.5 V. Therefore, the cable size (7/0.036) is suitable for that given load Example 2- What type and size of cable suits for given situation Load = 5.8 kW Volts = 230 V Length of Circuit = 35 meter ‘Temperature = 35°C (95°F) SI/ Metric / Decimal System ) Load Voltage = 230 V 5.8 KW = 5800 W Current = | = P/V = 5800 / 230 = 25.2.4 20% additional load current = (20/100) x5.2A=5A Total Load Current = 25.2 A+ 5A =30.2A From the table 1, size of cable is 7/1.04 for 31 A and temperature factor is 0.97 for 35°C from table 3. Current rating for 35°C = 31 x 0.97 = 30, It is less then the current carrying capacity of selected cable which is 31 A, therefore it is also suitable with respect to temperature. Now find the voltage drop for per ampere meter for this (7/1.04) cable from Table 5 which is 7 mV, But in our case, the length of cable is 35 meter. Therefore, the voltage drop for 35 meter cable would be; Actual Voltage drop for 35 meter = mV x I x L = (7/1000) x 30x35 = 7.6 V Allowable voltage drop = (2.5 x 230)/100 = 5.75 V Here, the actual voltage drop is greater than then the maximum allowable voltage drop of 5.75 \V Therefore the cable size (7/1 0a) is not suitahle for that aivan lnad Naw find aut valtane hpsielecrcal26a blogspot car/2017/06/suiate-cable-sizo irl 59sy, 1:21 AM Howto select cable size for various loads wih calculation wth rea life exarples? drop again by selecting higher cable size. Let's select 7/1.35 and calculate again. From table 5, cable rating for selected cable size is 40 A and voltage drop is 4.1 mV. So, actual voltage drop for 35 meter is Actual Voltage drop for 35 meter =(4.1/1000) x 40x35 = 7.35 V = 5.74V Now, The actual voltage drop is less than that of maximum allowable voltage drop. Therefore, the cable size (7/1.04) is suitable for that given load Example 3- Following Loads are connected in a building: For Sub-Circuit 1 2 lamps each 0 1000 W and 4 fans each of 80 W 2 TV each of 120 W For Sub-Circuit 2 6 Lamps each of 80 W and 5 sockets each of 100 W lamps each of 800 W If supply voltages are 230 V then calculate circuit current and Cable size for each Sub-Circuit? Solution: Total load of Sub-Circuit 1 = (2 x 1000) + (4 x 80) + (2x120) = 2000 W + 320 W + 240 W = 2560 w Current for Sub-Circuit P/V = 2560/230 = 11.1 A Total load of Sub-Circuit 2 = (6 x 80) + (5 x 100) + (4 x 800) = 480 W + 500 W + 3200 W= 4180 Ww Current for Sub-Circuit = PV = 4180/230 = 18.1A From the table, cable size for sub circuit 1 is 3/.029° (13 A) or 1/1.38 mm (13 A) and for sub- circuit 2 is 7/.029" (21 A) or 7/0.85 mm (24 A). Total Current drawn by both Sub-Circuits = 11.1 A+ 18.1 A= 29.27 A So, cable size for main-circuit is 7/.044" (34 A) hpsielecrical20a blogspot car/2017/0/suilate.cable-sizo Hind 69sy, 1:21 AM Howto select cable size for various loads wih calculation wth rea fe expos? Example 4-A 10 H.P (7.46 kW) three phase squirrel cage induction motor of continuous rating using StarDelta starting is connected through 400 V supply by three single core PVC cables run in conduit from 250 feet (76.2 m) away from multi-way distribution fuse board. Its full load current is 19 A. Average summer temperature in Electrical installation wiring is 35°C (95°F). Calculate the size of the cable for motor? Solution: Motor load = 10 HP = 10 x 746 = 7460 W (- Supply Voltage = 400 V (3-Phase) Length of cable = 250 feet (76.2 m) Motor full load Current = 19 A ‘Temperature factor for 35°C (95°F) = 0.97 (From Table 3) HP = 746 W) Size of cable for 19 A full load current is 7/0.36" (For 23 A) in the table, Here, 3-phase system and voltage drop is 5.3 V fro 100 feet. According to table 4 cable size 7/0.036 can be use. From the table 3, the temperature factor is 0.97 at 35°C and current carrying capacity of selected wire is 23 A. So, Current rating for 40°C (104"F) = 23 x 0.97 = 22.31 A It is less then the current carrying capacity of selected cable which is 23 A, therefore it is also suitable with respect to temperature. Load factor = 19/23 = 0.826 From the table 4, voltage drop is 5.3 V for selected cable at 100 feet and here, length of cable is 250 feet. therefore, Actual voltage drop (250 feet) = (5.3 x 250/100) x 0.826 = 10.94 V ‘And maximum Allowable voltage drop = (2.5/100) x 400 V= 10 V Here, the actual voltage drop is greater than then the maximum allowable voltage drop of 10 V. Therefore, the cable size (7/0.036) is not suitable for that given load. Now, find out voltage drop again by selecting higher cable size. Let's select 7/0.044 cable size and calculate again. Actual voltage drop (250 feet) = (4.1/100) x 250 x 0.826 = 8.46V ‘And Maximum allowable voltage drop = (2.5/100) x 400V= 10V Now, The actual voltage drop is less than that of maximum allowable voltage drop. Therefore, the cable size (7/0 04d is suitable for that civen nad hpsielecrical26a blog spe car/2017/06/suilaee-cable-sizo ind 79192, 1121 AM Howto select cable size for various loads wih calculation wth rea fe earrples? "~ housewiring installation wiring Popular posts from this blog Three phase electrical wiring system for home & multi-floor building jiya = June 08, 2017 In this article you will learn about how to do three phase wiring in home. Generally, the elctrical supply provider company install single phase energy meter for where requirements is 7.5 kW load in domestic area READ MORE How to control One Lamp from three/six different places and working principle of intermediate switch? = June 07, 2017 In this article we learn about how to control a lamp with 3 different switches at different places. This is very useful. For doing this we required two 2-way switch, 1 intermediate switch and a lamp. Connect all these at READ MORE ‘Theme images by € hpsielecrical20a bog spt car/2017/06/suitate.cable-sizo Hind a9sy, 1:21 AM Howto select cable size for various loads wih calculation wth rea life expos? Archive ¥ Labels v Report Abuse hpsielecrical20a blogspot car/2017/0/suilate.cable-sizo Hind 90