Cable selection project

Factory office installation

maximum demand sub- mains

cable
Each factory/warehouse consists of the
following loads
8- 250W mercury vapour lamps
4-60watt incandescent lamps
3-18watt fluorescent. External
1-500watt sodium vapour lamp. External
6-10A double single phase outlets
3-20A 3 phase outlets
1- 15A three phase storage hot water

Office

Lighting
8-double 36 watt fluorescent lights
Power
8- double10A single phase outlets
1- single 10A single phase outlet

Step 1
Divide the installation into circuits and
distribute these circuits across the three
phases
Calculate the maximum demand of the
installation
The maximum demand of the sub- mains
is the load on the heaviest loaded phase

Arrange into circuits

Factory

Circuit 1 (4-250W) lamps (R )

Circuit 2 (4-250W) lamps (W)
Circuit 3 (4-60watt) + 2 EF 60W (B)
Circuit 4 (3-18watt) F/lamps (W)
Circuit 5 (1x500watt SV lamps) (B)
Circuit 6 (2 double 10A) outlets (R)
Circuit 7 (2 double 10A) outlets (W)
Circuit 8 (2 double 10A) outlets (B)
Circuit 9 (20A 3 phase) outlet
Circuit 10 (20A 3 phase) outlet
Circuit 11(20A 3 phase) outlet
Circuit 12 (15A 3 phase) HWS

Office

Circuit13 (8 double36 watt fluorescent) (B)

Circuit14 (3 double 10A outlets)
(R)
Circuit15 (3 double 10A outlets)
(W)
Circuit16 (2 double 1 single 10A outlet) (B)

MD Sub-mains
using table C2

Factory
Circuit
no

1
2
3
4
5
6
7
8

Load
group

Load

calculation

(4-250W)MV lamps 1.5A each

4 x 1.5 = 6

(4-250W) MV lamps 1.5A each

4 x 1.5 = 6

(4-18W) energy saver 0. 05A each

2x60w exhaust fans at 0.3A each

(3-18W) fluorescent 0.12A each

0.12 3 .36

0.36

1-500w sodium vapour lamps 0.8

pf

500
2.72
230 0.8

2.72

Bi

2-10A double 1Phase outlets = 4

Bi

2-10A double 1Phase outlets =4

Bi

2-10A double 1Phase outlets =4

6
0.8

(0.05 4) (0.3 2) 0.8

1000

3 750
14.14
230

1000

3 750
14.14
230

1000

3 750
14.14
230

14.14
14.14
14.14

Maximum demand Sub-mains

Circuit
no

Load
group

Load

calculation

9
10
11
12

B (iii)

20A three phase outlet

Full load

20

20

20

B (iii)

20A three phase outlet

75% Full load

15

15

15

B (iii)

20A three phase outlet

75% Full load

15

15

15

15A three phase HWS

Full load

15

15

15

office

13
14
15

8-twin 36w fluorescent

8 0.78 6.24

B (i)

3-10A double outlets single

phase

B (i)

3-10A double outlets single

phase

6 750
19.56
230
6 750

16

B (i)

2-10A double 1-10A single

Outlets single phase

Maximum D

230

6.24
19.56
19.56

19.56

5 750w
16.3
230

16.3
104.7

104.7

105.6

Cable size for sub-main to

factory/warehouse unit1
The Maximum demand is 106A
Mains

Sub-mains

X90 SDI Cables double insulated buried in separate U/G conduit

Current carrying capacity T7/18 25mm = 135A
Voltage drop T41 Vc =1.62mV/Am

Vd

Vc L I 1.62 38 106

6.52 Volts
1000
1000

So 25mm X90 SDI Cables in separate conduits will satisfy both current and
voltage drop requirements.
Unit 1 has the longest run (38 metres) so 25mm will satisfy units 2 and 3

Installation load

The installation consists of the following loads.

Lighting
24 250W mercury vapour Lamps
24 2x36W Fluorescent Luminaires 0.78A each
12 18W fluorescent to replace 60W
8 18W Fluorescent
6 60W exhaust fans 0.3A each
3 500W

Installation load

Power
42 double 10A single phase outlets
3 single 10A single phase outlets
9 20A three phase outlets
3 3 phase HWS

Consumers Mains maximum demand

Load
Group

load

Calculation

24 250W mercury vapour

Lamps (8 per phase)

8 x 1.5 = 12

12

12

12

6.24

6.24

6.24

24 2x36W Fluorescent
Luminaires (8 per phase)

8 0.78 6.24

12 18W fluorescent (0.05A) to

replace 60W

4 x 0.05 = 0.2

0.2

0.2

0.2

6 60W exhaust fans (0.3A

each)

2 x 0.3 = 0.6

0.6

0.6

0.6

8 18W Fluorescent (0.12A)

3,3,2 per phase

0.12 x 3 =.36
0.12 x 2 = .24

0.36

0.36

0.24

2.71

2.71

2.71

3 500W

500
2.71
230 0.8

14 Double +1 single 10A single

outlets per phase (29 per phase)
87 outlets total

1000 28 750
95.65
230

95.65

95.65

95.65

9 20A three phase outlets

20 + 8 x 15 =140

140

140

140

3 - 15A 3phase HWS

3 x 15 = 45

45

45

45

302.8

302.8

302.7

MD

Cable Size consumers mains

The consumer mains are X90 SDI cables installed in conduit U/G for a
length of 40 metres
Determine the cable size to suit current and voltage drop requirements
Table 2.4 item 2 refers to Table 7/16
150mm = 330A The cable can carry the MD current
Check for voltage drop.
Table 41 Vc for 150mm conductors = 0.309mV/Am (60C) The cable
is rated at 90C and by choosing a Vc value at 60C this allows for
temperature rise under Short circuit conditions

0.309 40 303

3.745
1000
1000

Progressive Voltage drop

Consumers main
Volt drop 3.745
volts
40 metres
Turret

10 metres

20 metres
MSB

DB
unit3
DB
Unit 2

38 metres
Sub-main voltage drop 6.52 volts

3.745 Volts

6.52 Volts

DB
Unit 1

Progressive Voltage drop

distribution board unit 1
Consumers
mains

Sub-main

Final sub-circuits

5.57 volts allowed in all single phase

circuits
3 phase Value
3 phase value
9.735 Volts allowed in all 3 phase
3.745+6.52 = 10.265 volts 3 phase Therefore the circuits
3.745 volts

6.52 volts

3 phase voltage drop allowed in all 3 phase

circuits supplied from the DB Unit1 is 20
10.265 = 9.735 V
To determine the single phase voltage allowed in
final sub circuits

10.265 10.265

5.93 Volts
1
.
73
3

Therefore the single phase Voltage drop

allowed in all single phase circuits
supplied from distribution board Unit 1 is
11.5 5.93 = 5.57 Volts

Circuit arrangements
Cable
Maximum Installation Parameters
Designation demand

AZ/NZS
3008/1/1
Table No

column

Consumers
mains

302 A

XLPE (X90)
SDI enclosed UG

Table 2.4
Table 7

4
16

Sub-mains

106 A

X90 SDI enclosed U/G

Table 2.4
Table 7

4
18

4x250W MV
6A
Lamp Factory
2 circuits

TPS V90 installed with 3 other

circuits
De rate 0.78

Table 2.1
Table 9
Table 24

4
2
8

10A outlets
Factory

TPS V90 installed with 3 other

circuits spaced
De rate 0.87 item22

Table 2.1
Table 9
Table 24

4
2
8

16A

Cable
Maximum
designation demand

Installation
parameters

AS/NZS
3008
Table no

3 phase
outlets

TPS V90 installed

with 2 other circuits
On cable
De rate 0.82

Table 2.1
Table 12
Table 24

4
2
8

EF + Battens 0.8A
In Toilets

TPS unenclosed
3 other circuits on
cable tray up wall
from switchboard

Table 2.1
Table 9
Table 24
De-rate 0.88

4
2
8

HWS

15

TPS unenclosed
3 other circuits on
cable tray up wall
with 3 other circuits

Table 2.1
Table 12
Table 24
De-rate 0.88

4
2
8

500W SV

2.8A

TPS installed
enclosed U/G

Table 2.4
Table 9

20A

Column
no

4
16

Cable Size 20A 3 outlets

Distribution board Unit 1
Sub-main

Mains
U/G
turret
Determine the cable size for
the 20A 3 phase outlets 1
per circuit, longest run 38
metres The cable is 3core
TPS V 90 installed enclosed
in air. No de-rating for this
section. Unenclosed in air
spaced on perforated tray up
wall above switchboard 4
circuits

20
24.4
0.82
Table 12/4 a 4mm 2 cable 29A

Unit 1
DB

MSB

20A
3 outlet

1000 Vd
Vc
L I
1000 9.735

38 20
12.8mV / Am

To satisfy voltage drop requirements

Table 42 a 4 mm Cable with a Vc value
of 9.71 mV/Am value is required

Cable Size 20A 3 outlets

Distribution board Unit 1
Sub-main

Mains
U/G
turret

MSB

Determine the cable size for the 20A 3 phase outlets 1 per circuit,
Route length 25 metres
Current carrying capacity is the limiting factor in this circuit

20A
3 outlet
To satisfy Current carrying capacity, a
4mm TPS cable is required

Unit 1
DB

Cable Size 20A 3 outlets

Sub-main

Mains
U/G
turret

MSB

Unit 1
DB

Determine the cable size for the

20A 3 phase outlets 1 per circuit,
Route length 15 metres

20A
3 outlet

In this instance Voltage

drop is not the governing
factor. A 4mm cable is
required for CCC

10A single phase outlets

6 outlets in warehouse 2 per phase, (3 circuits).
Circuit 1 (38m route length) The outlet is at the end of the run
therefore use MD =10A
1000Vd 1000 5.57
Vc

14.65mV/A.m
L I
38 10
convert to three phase
14.65 0.86 12.69mV/A.m

Therefore from Table 42, 4mm cable is required for volt drop
Cable enclosed in conduit on wall with 3 0ther circuits spaced
( 4 circuits )
Table 9/6 4mm cable = 26A
De-rating Table 22 (0.9) 26 x 0.87 = 23.4A

10A single phase socket outlets

Circuit 2 (30m route length)
1000Vd 1000 5.57
Vc

18.56mV/A.m
L I
30 10
convert to three phase
18.56 0.86 16.07 mV/A.m

Therefore from Table 42 2.5mm with a Vc value of

15.6mV/A.m is required
Circuit 3 route length 20m route length can also be wired
in 2.5mm
Table 9 column 6 (2.5mm cable)=20Ax0.9 =18A
So a 2.5mm cable will satisfy both CCC and Vd

Light Circuits unit 1

Circuit 1 (4x250W mercury vapour)
Route length 38m
Maximum Demand 4 x 1.5A = 6A.
Circuit beaker rating 10A . Determine Cable size
1000Vd 1000 5.57
Vc

29.316mV / A.m
L I
38 5
convert to three phase Vc 0.866
29.31 0.866 25.39mV / A.m

So from Table 42 a 2.5mm cable with a Vc value of

15.6mV/A.m three phase 15.6 x 1.155 =18mV/A.m is
required

Light Circuits unit 1

Circuit 2 (4x250W mercury vapour)
Route length 44m
Maximum Demand 4 x 1.5A = 6A. See clause 3.5.2
50% of circuit protective device can be used
Circuit beaker rating 10A . Determine Cable size

1000Vd 1000 5.57

Vc

25.328mV / A.m
L I
44 5
convert to three phase Vc 0.866
25.318 0.866 21.925mV / A.m

So from Table 42 a 2.5mm cable with a Vc value of

15.6mV/A.m three phase 15.6 x 1.155 =18mV/A.m is
required

Circuit 3 four battens and 2 EF

Toilets
Route length 28m
1000Vd 1000 5.57
Vc

39.78mV / A.m
L I
28 5
convert to three phase Vc 0.866
39.78 0.866 34.45mV / A.m

So from Table 42 1.5mm cable is required

Table 9 column 6 (1.5mm cable = 14A)

Circuit 4 (3x 18W) Fluorescent

Route length 50m
1000Vd 1000 5.57
Vc

318.28V / A.m
L I
50 .36
convert to three phase Vc 0.866
318.28 0.866 275.63mV / A.m

Voltage drop is not a factor for this circuit

Either 1mm or 1.5mm can be used

Circuit 5 (500W) sodium Vapour

Route length 16m
TPS Cable V90 Installed enclosed U/G
Distribution
Board
500W Sodium vapour

1000Vd 1000 5.57

Vc

127.98mV / A.m
L I
16 2.72
convert to three phase Vc 0.866
127.98 0.866 110 .8mV / A.m

Voltage drop is not a factor for this circuit

Either 1mm or 1.5mm can be used

Hot Water Cylinder

3 phase 15A

Route length 28m

Cable 3core + E enclosed TPS V90
Table 12 column 2 (2.5mm = 23A)
Check Voltage drop

1000 Vd 1000 9.735

Vc

23.17mV/Am
L I
28 15
Table 41 (2.5mm = 15.6mm)Therefore 2.5mm Cable

Office
8-2x36W(0.78A) fluorescent one circuit
Route length 40m Use 10A MCB
Rule 3.6.2 50.% circuit protective device for voltage drop

1000 Vd 1000 5.57

Vc

27.85mV / A.m
L I
40 5
convert to three phase Vc 0.866
27.85 0.866 24.118 mV / A.m
Table 42 1.5mm = 28.6mV/Am.
Use 1.5mm cable

Office10A socket outlets

Circuit 14 (three double outlets)

Route length 22m TPS cable installed unenclosed in air Table 9
column 4 (2.5mm = 26A)Use 20MCB
Rule 3.6.2 (50.% circuit protective device for voltage drop)

1000Vd 1000 5.57

Vc

25.318mV / A.m
L I
22 10
convert to three phase Vc 0.866
25.318 0.866 21.925mV / A.m
Table 42
2.5mm = 15.6mV/Am
2.5mm Cable for all socket outlet circuits in the office.

Fault loop impedance

The earth fault-loop impedance in an MEN
system comprises the following parts, starting
and ending at the point of the fault.
a) The protective earthing conductor, (PE),
including the main earthing terminal/connection
or bar and MEN.
b) The neutral return path, consisting of the
neutral conductor, (N), between the main neutral
terminal or bar and the point at the transformer
(the earth return path RG to RB has a relatively
high resistance and may be ignored for an
individual installation in an MEN system)

Fault loop impedance

c) The path through the neutral point of the
transformer and the transformer winding.
d) The active conductors as far as the point of
the fault.
The earth fault-loop is normally regarded as
consisting of the following two parts i) conductors upstream or external to the
reference point; and
ii) conductors down stream or internal to the
reference point.
Refer to appendix B for detail

Path taken by an earth fault current

Earth fault-loop impedance

Fault current IA

Distributor's network

POS
MEN

Neutral
Bar

Main Earth

Faulty equipment
Soil resistance high between
electrodes

Determine maximum route length

to satisfy fault loop impedance.
The maximum length of a circuit can be
determined using Table B1
(Exceptions include circuits wired in 4mm
cable protected by a 16A or 20A Type C
MCB)
The maximum length for this example will
need to be calculated

Calculation 16A MCB

0.8

( )
0.8 230 4 2.5

16 7.5 22.5 10 3 (4 2.5)
109metres
A 4mm Cable protected by a 16A MCB can be run 109m and
not exceed the earth fault loop impedance requirements

Switchboards Units 1-3

120A Main switch

MCBS
L L L L L P P P P P
P HW L P P P
10 10 10 10 10 16 16 16 20 20 20 16 10 16 16 16

Main Switch Board