Sizing conductors

and selecting
protection devices

04

POWER GUIDE 2009 / BOOK 04

EX29008-couverture.indd I 30/01/09 15:07:49

 Care selection of the sizes of the conductors in wiring
Careful
syst
systems and the characteristics of protection devices will
ensu
ensure basic protection of the installation:

INTRO - Pro
Protection against overloads
- Lim
Limitation of voltage drops
- Pro
Protection against short-circuits
- Ch
Checking of the thermal stresses
- Pro
Protection against indirect contact

The complete calculation of installations has been found to be so long,

complex, and even daunting as to justify the ongoing development of practical
aids: calculation charts, note-boards, etc. and now software, such as XL PRO2
Calculation. We must not however let the absolute accuracy, reliability and
ease of use of these tools make us lose sight of the calculation principles
on which they are based. The purpose of this book is to cover the main
rules that are used for sizing conductors, wiring systems and their electrical
protection (against overloads, voltage drops, short-circuits and indirect
contact) according to the parameters of the installation: physical (type
of conductor, installation conditions, temperature, length of lines, etc.)
and electrical (power, prospective short-circuit, operating currents, etc.).
Examples of how they are determined are given for each parameter.
The complete process for estimating the short-circuit currents at all levels
in the installation is illustrated on page 54.
The rules for selecting and mounting wiring systems
are specified in standard IEC 60364-5-52.
CENELEC guide R064-003 gives a rigorous calculation method suitable
for calculation software. In practice two approximate methods are used.
These are called the conventional method and the composition method.

EX29008-couverture.indd II 30/01/09 15:07:49

 Overcurrents IT system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1. On the first fault . . . . . . . . . . . . . . . . . . . . . . . . . 39
Overloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 2. On the second fault . . . . . . . . . . . . . . . . . . . . . . 39
Short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 03 Checking the maximum protected lengths . . 40
Calculation principle for installations . . . . . . . . 04 Solutions when the tripping conditions
are not met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Protection against overloads 1. Use of residual current devices . . . . . . . . . . . . 45
Determination of the actual operating 2. Use of “low magnetic” circuit breakers
current IB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06 or curve B circuit breakers . . . . . . . . . . . . . . . . . . 45
3. Increasing the cross-section . . . . . . . . . . . . . . . 45
Cross-section of conductors . . . . . . . . . . . . . . . . 07 4. Creating additional equipotential links . . . . . . 45
1. Characteristics of the conductors. . . . . . . . . . . 08
2. Wiring systems: installation methods . . . . . . . 08 Estimation of short-circuits
3. Group of circuits . . . . . . . . . . . . . . . . . . . . . . . . 12
and calculation example
4. Ambient temperature . . . . . . . . . . . . . . . . . . . . 17
5. Risks of explosion . . . . . . . . . . . . . . . . . . . . . . . 19 Short-circuit value at the origin
6. Parallel conductors . . . . . . . . . . . . . . . . . . . . . . 19 of the installation . . . . . . . . . . . . . . . . . . . . . . . . . 46
7. Global correction factor . . . . . . . . . . . . . . . . . . . 19 1. Supply via HVA/LV transformer . . . . . . . . . . . . 46
8. Cross-section of the neutral conductor . . . . . . 22 2. Supply via the mains . . . . . . . . . . . . . . . . . . . . . 48
3. Supply via an alternator . . . . . . . . . . . . . . . . . . . 48
Devices for protection against overloads . . . . 23
1. Location and choice of protection devices . . . . 23 Short-circuit value at any point . . . . . . . . . . . . . 50
2. Exemption from protection against 1. Impedance method . . . . . . . . . . . . . . . . . . . . . . 50
overloads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2. Composition method . . . . . . . . . . . . . . . . . . . . . 52
3. Recommendation for no protection Calculation example . . . . . . . . . . . . . . . . . . . . . . 54
against overloads . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Conductors
Checking voltage drops
Selection and use of cables and conductors . . . 58
Checking voltage drops . . . . . . . . . . . . . . . . . . . . 24
Cable cores identification . . . . . . . . . . . . . . . . . . 65
Protection against short-circuits Wiring in assemblies . . . . . . . . . . . . . . . . . . . . . 66
Breaking capacity . . . . . . . . . . . . . . . . . . . . . . . 28 1. Cross-sections of conductors . . . . . . . . . . . . . 66
2. Selecting flexible bars . . . . . . . . . . . . . . . . . . . . 68
Checking the thermal stresses permitted
by conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1. Live conductors . . . . . . . . . . . . . . . . . . . . . . . . . 30
2. Protective conductors . . . . . . . . . . . . . . . . . . . . 31
Checking the maximum protected lengths . . . 32

Protection against indirect contact

TT system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
TN system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1. Breaking time . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2. Fault current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3. Maximum protected lengths . . . . . . . . . . . . . . . 38
01

EX29008_p1-15.indd 01 30/01/09 15:07:07

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Overcurrents
All live conductors in the installation (phase
and neutral) must in principle be protected
against overloads and short-circuits.

OVERLOADS
An overload is an overcurrent circulating when there > Infrared thermography
is no electrical fault in a circuit. It is caused by can be used to detect
under-sizing of the wiring system for the load overloads, as shown here
being supplied, or by the load being too high in a transformer winding
for the wiring system.
Protection devices must be provided to break any
overload current before the overheating of the
conductor damages its insulation, its connections
and the surrounding equipment. Protection against
overloads can be provided by fuses (type gG), circuit
breakers with thermal or electronic release or The devices for protecting the circuits
in the installation are not designed to
contactors with measurement relays. aM fuses
protect internal circuits in devices or flexible
do not provide protection against overloads. conductors (power supply cables of mobile
The rules for determining overload protection devices) connected to the power sockets.
are described on page 06. It may be necessary to design appropriate
separate protection devices if this is called
for by the risk of overcurrents (for example,
overload on motors).

> The concentration of the conductors

OVERLOADS

requires compliance with strict

installation rules and the application
of correction factors to the current-
carrying capacities of the cables
02

EX29008_p1-15.indd 02 30/01/09 15:07:08

 SHORT-CIRCUITS
A short-circuit is an overcurrent produced
by a minor impedance fault between conductors In principle, all the lines must be protected
with different potentials. It is accidental and can be against short-circuits.
due to clumsiness (dropping a tool, cutting a cable) Devices can be combined in order to increase
the breaking capacity (see the “Breaking and
or an equipment defect.
protection devices” book). Exemption from
Protection devices must be provided to limit and protection is also possible in certain cases.
break the short-circuit currents before their thermal The protection of conductors in parallel for the
(heating of the conductors, electric arcs) and same circuit must be subject to special wiring
mechanical (electrodynamic forces) effects become precautions.
harmful and dangerous. Protection against short-
circuits can be provided by fuses (type gG or aM),
by circuit breakers with magnetic relays or by circuit
breakers with electronic relays (overcurrent).
Their breaking capacities and circuit opening times
must be suitable for the circuit being protected.
The rules for determining short-circuit protection
are described on page 28 et seq.

Fault currents

In equipment or installations, fault currents between low value (a few mA), to avoid the risk of arcing. Caution:
live parts and exposed conductive parts generally the 2nd fault must be protected by a residual current
arise as a result of a fault or ageing of the insulation. device IAn < 300 mA. In hazardous situations it is strongly
The circulation of the current may, depending on the recommended that preventive maintenance is carried out
value it reaches, create sparks, or even set alight the based on monitoring the insulation value of the whole
surrounding equipment. The choice of the neutral installation: values indicated by the permanent insulation
earthing system determines the maximum value monitor (IT) or regular campaigns to measure the
of the fault currents. insulation resistance.
If there is a risk of fire: The presence of contaminants, humidity or the ageing
- The TN-C system is not allowed, as the currents can of the insulation leads to weak points in the insulation.
reach several kA and may even circulate in the structures If the test voltage value is significantly increased,
of the buildings a considerable reduction in the resistance value will be
SHORT-CIRCUITS

- The TN-S system is inadvisable unless residual current observed. The application of increasing measurement
devices with sensitivity IAn <300 mA are added voltages, for example: 500 V, 1000 V, 1500 V, 2500 V,
- The TT system is possible (limitation by residual current 5000 V, will reveal any defects if the insulation value
device) drops by more than 25% at each increasing voltage level.
- The IT system is recommended in intrinsic safety Caution: the test value must remain much lower than the
systems as the 1st fault current can be limited to a very dielectric strength of the installation (min. 2 U + 1000).

03

EX29008_p1-15.indd 03 30/01/09 15:07:08

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Overcurrents (continued)
CALCULATION PRINCIPLE FOR INSTALLATIONS
The conductors must be sized and the protection condi- Calculate the maximum short-circuit current
tions determined for each circuit in the installation. (Ikmax, fault at the origin of the circuit) and minimum
The procedure is identical for every circuit and involves short-circuit current (Ikmin, fault at the end
a number of steps, which are described below. of the circuit). These values are derived from
the supply voltage and the impedance of the fault
Calculate the actual operating current (IB)
loop (see p. 46).
of the wiring system. This value is derived by estimation
of the total load connected with the receivers on the Determine the characteristics of the short-
circuit concerned (see p. 06). circuit protection device: breaking capacity (Icu)
and magnetic trip threshold (or setting Im).
Determine the cross-section of the conductors
The breaking capacity must be greater than
to be used according to this actual operating current.
the maximum short-circuit current.
The current-carrying capacity (IZ) of a wiring system
The trip threshold will be determined
is dependent on the temperature it can withstand and
according to the minimum short-circuit
its dissipation conditions. The characteristics of the
current (see p. 28)
wiring system (type of core, type of insulation, number
of conductors) and its circulation conditions (installation Check the thermal stresses permitted
method, ambient temperature, group of several circuits) by the conductors, in particular for the overload
are therefore determining factors (see p. 07 to 22). and minimum short-circuit currents (see p. 29).
Select the overload protection device with the Check the maximum lengths protected against
required rating (In) and if necessary determine short-circuits. The lowest short-circuit current
its setting (Ir) (see p. 06). (at the end of the wiring system) must effectively
trip the protection device (see p. 32).
Calculate the voltage drop in the wiring system
according to its length and the actual operating Check the protection conditions against indirect
current. If this value exceeds the specified value, contact. The breaking time for a fault at the end
the cross-section of the conductors must be of a wiring system (minimum fault current) must
increased (see p. 24). be compatible with protecting people (see p. 36).
CALCULATION PRINCIPLE FOR INSTALLATIONS

Standards and exemptions

A device providing protection against overloads and short-circuits must be placed where a change of cross-section,
type, installation or construction method results in a reduction in the current-carrying capacity (IEC 60364-473).
If it were applied to the letter, this rule would lead to over-sizing of cross-sections for the fault conditions.
The standard therefore allows for there to be no protection device at the origin of the branch line in two cases.
1 - The protection device placed upstream effectively protects the branch line.
2 - The branch line is less than three metres long, is not installed near any combustible materials and every
precaution has been taken to limit the risks of short-circuits.

04

EX29008_p1-15.indd 04 30/01/09 15:07:08

 XL PRO 2 Calculation

Using the parameters of the installation,

XL Pro2 Calculation enables you to
determine the cross-sections of cables,
the protection devices, etc., then create a
complete technical folder (diagram of the
installation, dedicated calculation sheets,
etc.)

^ Characteristic and circulation conditions

< Selection of the parameters of the conductors
of the installation: type
and characteristics
of the source, regulatory
context, calculation
preferences, etc.

^ Selection and settings of protection devices

CALCULATION PRINCIPLE FOR INSTALLATIONS

< Diagram
of the installation

< Determination
of the operating
current for each ^ Calculation of all the parameters, printing
circuit out or exporting the results

05

EX29008_p1-15.indd 05 30/01/09 15:07:08

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

An electric current flowing in a conductor causes

a temperature rise proportional to the square
of the current: this is the Joule effect.
Protection against With this principle as the starting point,
the current-carrying capacity Iz of the conductor

overloads must be determined according to its cross-

section, its type and its installation conditions
(installation methods). This is a prerequisite
which will then enable suitable overload
protection to be chosen.

DETERMINATION OF THE ACTUAL OPERATING CURRENT IB

The actual operating current IB must not exceed the
rated current (rating In or setting Ir) of the protection
device, which itself must not exceed that of the
current-carrying capacity of the wiring system Iz.
Value Iz must be reduced by a factor R in the event
of fuse protection. Conductor supplying
It is therefore advisable to comply with the following: a group of circuits
IB < In < R x Iz (reduction factor Kc)
where:
R = 1 for circuit breakers
R = 0.75 for gG fuses < 16 A
R = 0.9 for gG fuses > 16 A
The values of factor R are the result of design
differences between the devices and between
the standards used to determine their rated currents.

Conductors supplying
For adjustable circuit breakers, it is advisable applications or terminal
for Iz to be higher than the nominal rating circuits (utilization
In of the device. There will be no adverse factor)
consequences if there is an unsuitable thermal
setting Ir or a change in the operating current
IB.
DETERMINING THE ACTUAL OPERATING CURRENT IB

The determination of the actual operating currents

Load areas of a wiring system (IB) in conductors supplying terminal circuits or
receivers must incorporate utilization factors
connected with the type of load (cos ϕ, output,
Value In (Ir) must be
inrush current, etc.).
in the green area
An example for a lighting circuit is given
In the red area, the wiring on the next page.
system is overloaded
The actual operating currents (IB) in the conductors
R × Iz In the orange area, the supplying groups of circuits can be reduced by a
protection is under-rated with factor kc, known as coincidence, which takes account
In (Ir) a risk of unwanted tripping of the fact that not all the circuits and their respective
Value Iz represents the loads are in use at the same time.
IB
maximum current that the
wiring system can withstand
continuously without adversely
affecting its service life.

06

EX29008_p1-15.indd 06 30/01/09 15:07:09

 In the informative appendix of standard
Example IEC 60364-1 it is recommended that the
coincidence and operating factors are checked.
Calculation of the operating current of a 230 V circuit In France, UTE guide C 15-105 describes
supplying forty 2 x 36 W fluorescent tube strip lights. a method for determining the maximum
Theoretical power: 2 x 36 x 40 = 2880 W operating current, based on knowledge of the
2880 power of each load circuit for which various
i.e. a theoretical current of = 12.5 A
230 factors are given.
which should be increased by the factors connected • Reduction factors:
with the cos ϕ and the output. - Coincidence factor connected with the
large number of circuits (for example, power
Generic cos ϕ values are given for various types
sockets)
of receiver (see the “Power analysis and selection
- Operating factor (or load factor) generally set
of sources” book). The output values will be given
at between 0.7 and 0.8.
in the manufacturer's data.
• Increasing factors:
If a factor of 1.8 is used for the strip lights, - Factor connected with the output or
the following operating current is obtained downgraded cos ϕ (fluorescent bulbs) and
IB = 12.5 x 1.8 = 22.5 A overcurrents (motor starting)
- Factor allowing for extension of the
installation.

DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

The determination of the cross-section of the
conductors is based on knowledge of the maximum Determining the cross-section using the table DETERMINING THE CROSS-SECTIONS OF CONDUCTORS
current-carrying capacity of the wiring system, of current-carrying capacities (page 20)
which is itself determined based on the conductors
and their operating conditions. Reference Type of
Standard IEC-60364-5-52 determines the current method conductor
values according to the basic operating principles
C PVC 3 PVC 2 PR 3 PR
for installations and safety of people. The main D
elements are given below. E
F
PVC 3
PVC 3
PVC 2 PR 3
PVC 2 PR
The table of current-carrying capacities (page 20) 1.5 13 13.5 14.5 15.5 17 18.5 19.5 22 23 24
Size (mm2) 2.5 17.5 18 19.5 21 23 25 27 30 31 33
can be used to directly determine the cross-section 4 23 24 26 28 31 34 36 40 42 45
of the conductors according to: 6 29 31 34 36 40 43 46 51 54 58

- Type of conductor 10 39 42 46 50 54 60 63 70 75 80
16 52 56 61 68 73 80 85 94 100 107
- Reference method (installation method) 25 68 73 80 89 95 101 110 119 127 135
Copper
- The theoretical current-carrying capacity Iz (Izth) 35 - - - 110 117 126 137 147 158 169
50 - - - 134 141 153 167 179 192 207
Izth is calculated by applying all the correction fac- 70 - - - 171 179 196 213 229 246 268
tors f to the operating current value IB. The factors f 95 207 216 238 258 278 298 328

are determined according to the installation method, Cross-section Current-carrying

grouping, temperature, etc. of the conductor capacity
I
IB = Izth × f giving Izth = B
f
07

EX29008_p1-15.indd 07 30/01/09 15:07:09

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against overloads

(continued)
1 CHARACTERISTICS OF THE CONDUCTORS
The following information is taken into consideration. permissible temperature during operation, XLPE
- The type of core: copper or aluminium. or EPR for insulation that can withstand 90°C and PVC
- The type of insulation, which defines the maximum for insulation that can withstand 70°C

Maximum operating temperatures according to the type of insulation (IEC 60344-5-52)

Type of insulation Maximum temperature(1) ˚C
Polyvinyl chloride (PVC) Conductor: 70

Cross-linked polyethylene (XLPE) and ethylene-propylene (EPR) Conductor: 90(1)

Mineral (with or without PVC sheath, and accessible) Sheath: 70

Mineral (without sheath, accessible and not in contact with
Sheath: 105(2)
combustible materials)
(1) If a conductor operates at a temperature greater than 70˚C, it is advisable to check that the equipment connected to this conductor
is suitable for the final temperature of the connection.
(2) Higher operating temperatures may be permitted for certain types of insulation, depending on the type of cable, its ends,
the environmental conditions and other external influences.

2 WIRING SYSTEMS: INSTALLATION

METHODS
The standard defines a number of installation methods
DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

which represent the various installation conditions.

In the following tables, they are divided into groups
and defined by the letters A to G which determine
how to read the table of the current-carrying
capacities in conductors (see p. 20).
If several installation methods are used along the
length of the wiring system, the methods for which
the thermal dissipation conditions are the least
favourable must be chosen.

There is no explicit provision in the standard

on the determination of the cross-section of
conductors inside low voltage distribution
boards. However standard IEC 60439-1 defines
the currents (used for the temperature rise
tests) for PVC insulated copper conductors.
A “guide” table taking account of work
practices is given on p. 66.

08

EX29008_p1-15.indd 08 30/01/09 15:07:10

 < In the XL Pro2 Calculation software,
the reference installation methods
are called “installation groups”.

“Installation group” according to the type of cable

Cable type
Installation group
Insulated conductors Single-core cables Multi-core cables
(A1) In a thermally insulated wall • •
(A1) In conduit in a thermally insulated wall • •
(A1-A2) In a thermally insulated wall •
(B1-B2) In conduit on a wooden wall • • •
( C ) On a wooden wall • •
( C ) Fixed on a wooden wall • •
( D ) In ducts in the ground • •
( E ) In free air •
( F ) In free air • DETERMINING THE CROSS-SECTIONS OF CONDUCTORS
( G ) Spaced in free air •

(A1) In a thermally insulated wall Insulated conductors and single-core cables Multi-core cables

In conduit in a thermally insulated wall

In conduit in architrave

In conduit in window frame

(A1) In conduit in a thermally insulated wall Insulated conductors and single-core cables Multi-core cables

Run in mouldings -

(A2) In a thermally insulated wall Insulated conductors and single-core cables Multi-core cables

In conduit in a thermally insulated wall -

09

EX29008_p1-15.indd 09 30/01/09 15:07:10

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against overloads

(continued)

(B1-B2) in conduit on wooden wall Insulated conductors Single-core cables Multi-core cables

In conduit on a wooden, or masonry wall (B1) (B1) (B2)

In conduit in masonry (B1) (B1) (B2)

In cable trunking in a wooden wall-run horizontally (B1) (B1) (B2)

In cable trunking in a wooden wall-run vertically (B1) (B1) (B2)

In suspended cable trunking (B1) (B1) (B2)

In skirting trunking (B1) (B1) (B2)

In embedded trunking (B1) (B1) (B2)

In a building void (V > 20 De) - (B1) (B1)

In cable ducting in a building void (V > 20 De) (B1) (B1) (B1)

In a celling void (5 De < V < 50 De) - (B1) (B1)

In a suspended floor (5 De < V < 50 De) - (B1) (B1)

In cable ducting in a masonry(5 De < V < 50 De) (B1) - -

In flush cable trunking in the floor (B1) (B1) (B2)

In conduit in an cable unventilated cable channel
(V > 20 De)
(B1) (B1) -
DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

In conduit in an open or ventilated cable channel in the

(B1) (B1) (B1)
floor run horizontally or vertically

In cable ducting in building void (1,5 De < V < 20 De) (B2) (B2) (B2)

In cable ducting in masonry (1,5 De < V < 5 De) (B2) - -

In conduit in an cable unventilated cable channel
(1,5 De < V < 20 De)
(B2) (B2) -

In building void (1,5 De < V < 20 De) - (B2) (B2)

In celling void (1,5 De < V < 5 De) - (B2) (B2)

In a suspended floor (1,5 De < V < 5 De) - (B2) (B2)

(C) on wooden wall Insulated conductors Single-core cables Multi-core cables

Direct in masonry without added mechanical

protection
-

Direct in masonry with added mechanical protection -

10

EX29008_p1-15.indd 10 30/01/09 15:07:11

 (C) Fixed on wooden wall Insulated conductors Single-core cables Multi-core cables

Fixed on wooden wall -

Fixed directly under a wooden ceiling -

(D) In ducts in the ground Insulated conductors Single-core cables Multi-core cables

In conduit or in cable ducting in the ground -

Direct in the ground without added mechanical
protection
-

Direct in the ground with added mechanical protection -

(E -F) In free air Insulated conductors Single-core cables Multi-core cables

On unperforated tray - (F) (E)

On perforated tray-Horizontally-Touching - (F) (E)

On perforated tray-Vertically-Touching - (F) (E)

On perforated tray-horizontally-Trefoil - (F) (E)

DETERMINING THE CROSS-SECTIONS OF CONDUCTORS
On perforated tray-vertically-Trefoil - (F) (E)

On brackets or on wire mesh-touching - (F) (E)

On brackets or on wire mesh-trefoil - (F) (E)

Space more than 0,3 times cable diameter from a wall
touching
- (F) (E)
Space more than 0,3 times cable diameter from a wall
trefoil
- (F) (E)

On ladder touching - (F) (E)

On ladder trefoil - (F) (E)

Suspended from or incorporating from a support wire - (F) (E)

(G) Spaced in free air Insulated conductors Single-core cables Multi-core cables

On insulators spaced horizontally - -

11

EX29008_p1-15.indd 11 30/01/09 15:07:15

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against overloads

(continued)
3 GROUPS OF CIRCUITS
The tables giving the installation methods also refer to specific tables to be used to determine the correction
factors connected with the group of circuits and conduits

Reduction factors for groups of more than one circuit or of more than one multi-core cable
to be used with current-carrying capacities
Reference Arrangement Number of circuit or multi-core cables
method (cables touching) 1 2 3 4 5 6 7 8 9 12 16 20
Bunched in air, on a surface,
A to F 1.00 0.80 0.70 0.65 0.60 0.57 0.54 0.52 0.50 0.45 0.41 0.38
embedded or enclosed
Single layer on wall, floor
1.00 0.85 0.79 0.75 0.73 0.72 0.72 0.71 0.70
or unperforated tray
C
Single layer fixed directly No further
0.95 0.81 0.72 0.68 0.66 0.64 0.63 0.62 0.61 reduction factor
under a wooden ceiling
for more than nine
Single layer on a perforated circuits or multi-
1.00 0.88 0.82 0.77 0.75 0.73 0.73 0.72 0.72
horizontal or vertical tray core cables
E and F
Single layer on ladder support
1.00 0.87 0.82 0.80 0.80 0.79 0.79 0.78 0.78
or cleats etc.
These factors are applicable to uniform groups of cables, equally loaded.
Where horizontal clearances between adjacent cables exceeds twice their overall diameter, no reduction factor need be applied.
The same factors are applied to:
– groups of two or three single-core cables;
– multi-core cables.
If a system consists of both two- and three-core cables, the total number of cables is taken as the number of circuits,
DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

and the corresponding factor is applied to the tables for two loaded conductors for the two-core cables, and to the tables
for three loaded conductors for the three-core cables.
If a group consists of n single-core cables it may either be considered as n/2 circuits of two loaded conductors or n/3 circuits
of three loaded conductors.
The values given have been averaged over the range of conductor sizes and types of installation included in tables, the overall
accuracy of tabulated values is within 5%.
For some installations and for other methods not provided for in the above table, it may be appropriate to use factors calculated
for specific cases.

12

EX29008_p1-15.indd 12 30/01/09 15:07:17

 Reduction factors for groups of more than one circuit, cables laid directly in the ground
Installation method D - Single-core or multi-core cables
Duct to duct clearance (a)
Number
of cables Nil (ducts One cable
0.125 m 0.25 m 0.5 m
touching) diameter
2 0.75 0.80 0.85 0.90 0.90
3 0.65 0.70 0.75 0.80 0.85
4 0.60 0.60 0.70 0.75 0.80
5 0.55 0.55 0.65 0.70 0.80
6 0.50 0.55 0.60 0.70 0.80

Multi-core cables
a a

Single-core cables
a a

Values given apply to an installation depth of 0,7 m and a soil thermal resistivity of 2,5 K.m/W. They are average values for the range
of cable sizes and types quoted for tables. The process of averaging, together with rounding off, can result in some cases in errors
up to ±10%. (Where more precise values are required they may be calculated by methods given in IEC 60287-2-1).

DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

< Grouping circuits together results

in a reduction of the current-carrying
capacity (application of a correction factor)
13

EX29008_p1-15.indd 13 30/01/09 15:07:17

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against overloads

(continued)

Reduction factors for groups of more than one circuit, cables laid in ducts in the ground
Installation method D
Multi-core cables in single-way ducts

Number Cable to cable clearance (a)

of cables Nil (ducts touching) 0.25 m 0.5 m 1.0 m
2 0.85 0.90 0.95 0.95

3 0.75 0.85 0.90 0.95

4 0.70 0.80 0.85 0.90

5 0.65 0.80 0.85 0.90

6 0.60 0.80 0.80 0.90

Multi-core cables
a

Values given apply to an installation depth of 0,7 m and a soil thermal resistivity of 2,5 K·m/W. They are average values for the range
of cable sizes and types quoted for tables. The process of averaging, together with rounding off, can result in some cases in errors
up to ±10 %. Where more precise values are required they may be calculated by methods given in IEC 60287.

Single-core cables in single-way ducts

Number of Duct to duct clearance (a)

single-core circuits
DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

of two or three cables Nil (ducts touching) 0.25 m 0.5 m 1.0 m

2 0.80 0.90 0.90 0.95

3 0.70 0.80 0.85 0.90

4 0.65 0.75 0.80 0.90

5 0.60 0.70 0.80 0.90

6 0.60 0.70 0.80 0.90

Single-core cables
a a

Values given apply to an installation depth of 0,7 m and a soil thermal resistivity of 2,5 K·m/W. They are average values
for the range of cable sizes and types considered in tables. The process of averaging, together with rounding off,
can result in some cases in errors up to ±10%. Where more precise values are required they may be calculated by methods
given in IEC 60287

14

EX29008_p1-15.indd 14 30/01/09 15:07:18

 Reduction factors for groups of more than one multi-core cable to be applied
to reference ratings for multi-core cables in free air - Method of installation E
Number Number of cables
Method of installation in table
of trays 1 2 3 4 6 9

1 1.00 0.88 0.82 0.79 0.76 0.73

2 1.00 0.8 7 0.80 0.77 0.73 0.68
3 1.00 0.86 0.79 0.76 0.7 1 0.66
≥ 20 mm
Perforated
trays(1) De
1 1.00 1.00 0.98 0.95 0.91 -
2 1.00 0.99 0.96 0.92 0.87 -
3 1.00 0.98 0.95 0.91 0.85 -
≥ 20 mm

≥ 225 mm
1 1.00 0.88 0.82 0.78 0.73 0.72
2 1.00 0.88 0.8 1 0.76 0.7 1 0.70

vertical
perforated
trays(2)
≥ 225 mm
1 1.00 0.9 1 0.89 0.88 0.87 -
De 2 1.00 0.9 1 0.88 0.87 0.85 -
DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

1 1.00 0.8 7 0.82 0.80 0.79 0.78

2 1.00 0.86 0.80 0.78 0.76 0.73
3 1.00 0.85 0.79 0.76 0.73 0.70
≥ 20 mm
Ladder
supports,
De
cleats, etc.(1)
1 1.00 1.00 1.00 1.00 1.00 -
2 1.00 0.99 0.98 0.97 0.96 -
3 1.00 0.98 0.97 0.96 0.93 -
≥ 20 mm

Values given are averages for the cable types and range of conductor sizes considered in tables. The spread of values is generally
less than 5%.
Factors apply to single layer groups of cables as shown above and do not apply when cables are installed in more than one layer
touching each other. Values for such installations may be significantly lower and must be determined by an appropriate method
(1) Values are given for vertical spacings between trays of 300 mm and at least 20 mm between trays and wall. For closer spacing
the factors should be reduced.
(2) Values are given for horizontal spacing between trays of 225 mm with trays mounted back to back. For closer spacing the factors
should be reduced

15

EX29008_p1-15.indd 15 30/01/09 15:07:18

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against overloads

(continued)

Reduction factors for groups of more than one circuit of single-core cables (1) to be applied
to reference rating for one circuit of single-core cables in free air – Method of installation F
Number of three-phase circuits(4) Use as a
Number
Method of installation multiplier to
of trays 1 2 3 rating for

1 0.98 0.91 0.87 Three cables

Perforated trays(2) 2 0.96 0.87 0.81 in horizontal
3 0.95 0.85 0.78 formation
≥ 20 mm

≥ 225 mm Three cables

Vertical perforated 1 0.96 0.86 -
in vertical
trays(3) 2 0.95 0.84 -
formation

1 1.00 0.97 0.96 Three cables

Ladder support, 2 0.98 0.93 0.89 in trefoil
cleats, etc.(2) 3 0.97 0.90 0.86 horizontal
≥ 20 mm

De
≥ 2De 1 1.00 0.98 0.96
Perforated trays(2) 2 0.97 0.93 0.89
3 0.96 0.92 0.86
≥ 20 mm
DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

≥ 225 mm
Three cables
Vertical perforated ≥ 2De 1 1.00 0.91 0.89
in trefoil
trays(3) 2 1.00 0.90 0.86
arrangement
De

De
≥ 2De 1 1.00 1.00 1.00
Ladder support, 2 0.97 0.95 0.93
cleats, etc.(2) 3 0.96 0.94 0.94
≥ 20 mm

Values given are averages for the cable types and range of conductor sizes considered in tables. The spread of values is generally
less than 5%.
(1) Factors are given for single layers of cables (or trefoil groups) as shown in the table and do not apply when cables are installed in more
than one layer touching each other. Values for such installations may be significantly lower and must be determined by an appropriate
method.
(2) Values are given for vertical spacings between trays of 300 mm. For closer spacing the factors should be reduced.
(4) Values are given for horizontal spacing between trays of 225 mm with trays mounted back to back and at least 20 mm between
the tray and any wall. For closer spacing the factors should be reduced.
(5) For circuits having more than one cable in parallel per phase, each three phase set of conductors should be considered as a circuit
for the purpose of this table.

16

EX29008_p16-31.indd 16 30/01/09 15:05:05

 4 AMBIENT TEMPERATURE The ambient temperature around cables must
The ambient temperature has a direct influence not be confused with that taken into account
for the protection devices, which is the internal
on the sizing of the conductors.
temperature of the distribution board in which
The temperature to be taken into account is that
these protection devices are installed.
of the air around the cables (open air installation),
and that of the ground for buried cables.
The following tables, taken from standard
IEC 60364-5-52, can be used to determine the
correction factor to be applied for temperatures
ranging from 10 to 80°C.
The basic temperature in air is given at 30°C and that
of the ground at 20°C for all these tables.

Correction factors for ambient air temperatures other than 30°C

to be applied to the current-carrying capacities for cables in the air
Insulation
Ambient
temperature(1) Mineral
(˚C) PVC XLPE and EPR PVC covered or bare and bare not exposed
exposed to touch 70°C to touch 105°C

10 1.22 1.15 1.26 1.14

15 1.17 1.12 1.20 1.11
20 1.12 1.08 1.14 1.07 DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

25 1.06 1.04 1.07 1.04

35 0.94 0.96 0.93 0.96
40 0.87 0.91 0.85 0.92
45 0.79 0.87 0.87 0.88
50 0.71 0.82 0.67 0.84
55 0.61 0.76 0.57 0.80
60 0.50 0.71 0.45 0.75
65 - 0.65 - 0.70
70 - 0.58 - 0.65
75 - 0.50 - 0.60
80 - 0.41 - 0.54
85 - - - 0.47
90 - - - 0.40
95 - - - 0.32
(1) For higher ambient temperatures, consult manufacturer

17

EX29008_p16-31.indd 17 30/01/09 15:05:05

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against overloads

(continued)

Correction factors for ambient ground temperatures other than 20°C

to be applied to the current-carrying capacities for cables in ducts in the ground
Insulation
Ground temperature ˚C
PVC XLPE and EPR

10 1.10 1.07

15 1.05 1.04

25 0.95 0.96

30 0.89 0.93

35 0.84 0.89

40 0.77 0.85

45 0.71 0.80

50 0.63 0.76

55 0.55 0.71

60 0.45 0.65

65 - 0.60

70 - 0.53

75 - 0.46

80 - 0.38
DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

Correction factor for cables in buried ducts for soil thermal resistivities other than 2,5 K.m/W
to be applied to the current-carrying capacities for reference method D
Thermal resistivity (K.m/W) 1 1.5 2 2.5 3

Correction factor 1.18 1.1 1.05 1 0.96

The correction factors given have been averaged over the range of conductor sizes and types of installation considered in tables.
The overall accuracy of correction factors is within ±5%.
The correction factors are applicable to cables drawn into burried ducts; for cables laid direct in the ground the correction factors for ther-
mal resistivities less than 2,5 K.m/W will be higher. Where more precise values are required they may be calculated by methods given in
IEC 60287.
The correction factors are applicable to ducts buried at depths of up to 0,8 m.

18

EX29008_p16-31.indd 18 30/01/09 15:05:05

 5 RISKS OF EXPLOSION 7 GLOBAL CORRECTION FACTOR
In installations where there is a risk of explosion When all the specific correction factors are known,
(presence, processing or storage of materials which it is possible to determine the global correction factor
are explosive or have a low flash point, including the f, which is equal to the product of all the specific
presence of explosive dust), wiring systems must factors. The procedure then consists of calculating
include appropriate mechanical protection and the the theoretical current-carrying capacity Izth of the
current-carrying capacity will be subject to a reduction wiring system:
factor. The description and installation rules are given Izth = IB
in standard IEC 60079. f

Knowing Izth then enables reference to be made to the

6 PARALLEL CONDUCTORS tables for the current-carrying capacities (see p. 20)
As long as the arrangement of the conductors com- for determining the necessary cross-section.
plies with the grouping rules, the current-carrying Read from the column corresponding to the type
capacity of the wiring system can be considered as of conductor and the reference method.
being equal to the sum of the current-carrying capaci- Then simply choose in the table the current-carrying
ties of each conductor to which the correction factors capacity value immediately above the Izth value to find
connected with the group of conductors are applied. the cross-section.

A tolerance of 5% on the value of Iz is gene-

rally permitted. For example, an operating
current IB of 140 A would lead to the selection
of a 35 mm2 cross-section with a current-
carrying capacity of 169 A. Applying this DETERMINING THE CROSS-SECTIONS OF CONDUCTORS
tolerance enables a smaller cross-section
of 25 mm2 to be chosen, which can then withs-
tand a current of 145 A (138 + 0.5% = 145 A).

In the XL Pro2 Calculation software, this tolerance

is taken into account by “K user”

19

EX29008_p16-31.indd 19 30/01/09 15:05:05

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against overloads

(continued)

Current-carrying capacities in amperes

Reference
Number of loaded conductors and type of insulation(1)
methods
A1 PVC 3 PVC 2 PR 3 PR 2
A2 PVC 3 PVC 2 PR 3 PR 2
B1 PVC 3 PVC 2 PR 3 PR 2
B2 PVC 3 PVC 2 PR 3 PR 2
C PVC 3 PVC 2 PR 3 PR 2
D PVC 2 PVC 3 PR 2 PR 3
E PVC 3 PVC 2 PR 3 PR 2
F PVC 3 PVC 2 PR 3 PR 2
1.5 13 13.5 14.5 15.5 17 18.5 19.5 22 23 24 26 - 22 18 26 22
Size (mm2) 2.5 17.5 18 19.5 21 23 25 27 30 31 33 36 - 29 24 34 29
4 23 24 26 28 31 34 36 40 42 45 49 - 38 31 44 37
6 29 31 34 36 40 43 46 51 54 58 63 - 47 39 56 46
10 39 42 46 50 54 60 63 70 75 80 86 - 63 52 73 61
16 52 56 61 68 73 80 85 94 100 107 115 - 81 67 95 79
25 68 73 80 89 95 101 110 119 127 135 149 161 104 86 121 101
Copper 35 - - - 110 117 126 137 147 158 169 185 200 125 103 146 122
50 - - - 134 141 153 167 179 192 207 225 242 148 122 173 144
70 - - - 171 179 196 213 229 246 268 289 310 183 151 213 178
95 - - - 207 216 238 258 278 298 328 352 377 216 179 252 211
120 - - - 239 249 276 299 322 346 382 410 437 246 203 287 240
150 - - - - 285 318 344 371 395 441 473 504 278 230 324 271
185 - - - - 324 362 392 424 450 506 542 575 312 258 363 304
DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

240 - - - - 380 424 461 500 538 599 641 679 361 297 419 351
300 - - - - - - - - - - - - 408 336 474 396
2.5 13.5 14 15 16.5 18.5 19.5 21 23 24 26 28 - 22 18.5 26 22
Size (mm2) 4 17.5 18.5 20 22 25 26 28 31 32 35 38 - 29 24 34 29
6 23 24 26 28 32 33 36 39 42 45 49 - 36 30 42 36
10 31 32 36 39 44 46 49 54 58 62 67 - 48 40 56 47
16 41 43 48 53 58 61 66 73 77 84 91 - 62 52 73 61
25 53 57 63 70 73 78 83 90 97 101 108 121 80 66 93 78
35 - - - 86 90 96 103 112 120 126 135 150 96 80 112 94
Aluminium 50 - - - 104 110 117 125 136 146 154 164 184 113 94 132 112
70 - - - 133 140 150 160 174 187 198 211 237 140 117 163 138
95 - - - 161 170 183 195 211 227 241 257 289 166 138 193 164
120 - - - 186 197 212 226 245 263 280 300 337 189 157 220 186
150 - - - - 226 245 261 283 304 324 346 389 213 178 249 210
185 - - - - 256 280 298 323 347 371 397 447 240 200 279 236
240 - - - - 300 330 352 382 409 439 470 530 277 230 322 308
300 - - - - - - - - - - - - 313 260 364 308
(1) PVC 2: PVC insulation, 2 loaded conductors - PVC 3: PVC insulation, 3 loaded conductors - PR 2: XLPE or EPR insulation, 2 loaded
conductors - PR 3: XLPE or EPR insulation, 3 loaded conductors.
Use PVC 2 or PR 2 for single phase or two-phase circuits and PVC 3 or PR 3 for three-phase circuits.
20

EX29008_p16-31.indd 20 30/01/09 15:05:05

 Example of determining a three-phase circuit constituting the link between
a main distribution board and a secondary distribution board
Hypotheses
• The estimation of the loads has enabled the operating current of the conductors to be calculated: IB = 600 A
• The wiring system consists of single-core copper cables with PR insulation
• The conductors are installed touching one another in perforated cable ducting
• Preference is given to install the cables in parallel to limit the unit cross-section to 150 mm2

Solution
Installing single-core cables in a perforated cable tray corresponds to reference method F

(E -F) In free air Insulated conductors Single-core cables Multi-core cables

On unperforated tray - (F) (E)

On perforated tray-Horizontally-Touching - (F) (E)

< Extract from
the installation
On perforated tray-Vertically-Touching - (F) (E)
methods table
On perforated tray-horizontally-Trefoil - (F) (E)
(see p. 11)

If a single conductor per phase is sufficient, no correction need be applied.

If two conductors per phase are necessary, a reduction factor of 0.88 must be applied.

Reference Arrangement Number of circuit or multi-core cables

method (cables touching) 1 2 3 4 5 6 7 8 9 12 16 20
Bunched in air, on a surface,
A to F 1.00 0.80 0.70 0.65 0.60 0.57 0.54 0.52 0.50 0.45 0.41 0.38
embedded or enclosed
Single layer on wall, floor
< Extract from the table
C
or unperforated tray
1.00 0.85 0.79 0.75 0.73 0.72 0.72 0.71 0.70
giving the correction
No further DETERMINING THE CROSS-SECTIONS OF CONDUCTORS
Single layer fixed directly
under a wooden ceiling
0.95 0.81 0.72 0.68 0.66 0.64 0.63 0.62 0.61 reduction factor factors for groups
for more than nine
Single layer on a perforated
1.00 0.88 0.82 0.77 0.75 0.73 0.73 0.72 0.72 circuits or multi- (see p. 12)
horizontal or vertical tray core cables
E and F
Single layer on ladder support
1.00 0.87 0.82 0.80 0.80 0.79 0.79 0.78 0.78
or cleats etc

The theoretical value Iz will therefore be determined by: Izth = IB = 600 = 682 A i.e. 341 A per conductor.
f 0,88
C PVC 3 PVC 2 PR 3 PR 2
D PVC 2 PVC 3 PR 2 PR
Reading from the table of current- E PVC 3 PVC 2 PR 3 PR 2
F PVC 3 PVC 2 PR 3 PR 2
carrying capacities (opposite page) 1.5 13 13.5 14.5 15.5 17 18.5 19.5 22 23 24 26 - 22 18 26 22
Size (mm2) 2.5 17.5 18 19.5 21 23 25 27 30 31 33 36 - 29 24 34 29
For a PR 3 conductor in reference 4 23 24 26 28 31 34 36 40 42 45 49 - 38 31 44 37
6 29 31 34 36 40 43 46 51 54 58 63 - 47 39 56 46
method F and a current-carrying 10 39 42 46 50 54 60 63 70 75 80 86 - 63 52 73 61
capacity of 382 A (value immediately 16 52 56 61 68 73 80 85 94 100 107 115 - 81 67 95 79
above 341 A) the table gives 25 68 73 80 89 95 101 110 119 127 135 149 161 104 86 121 101
Copper 35 - - - 110 117 126 137 147 158 169 185 200 125 103 146 122
a cross-section of 120 mm2. - - - 134 141 153 167 179 192 207 225 242 148 122 173 144
50
70 - - - 171 179 196 213 229 246 268 289 310 183 151 213 178
95 - - - 207 216 238 258 278 298 328 352 377 216 179 252 211
120 - - - 239 249 276 299 322 346 382 410 437 246 203 287 240
150 - - - - 285 318 344 371 395 441 473 504 278 230 324 271

21

EX29008_p16-31.indd 21 30/01/09 15:05:05

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against overloads

(continued)
of the live conductors of multi-core cables is chosen
8 CROSS-SECTION OF THE NEUTRAL by increasing current IB.
CONDUCTOR Standard IEC 60364-5-52 gives a table showing
In principle, the neutral must be the same cross-sec- the correction factors according to the THD, followed
tion as the phase conductor in all single phase circuits. by an example of determining the current-carrying
In three-phase circuits with a cross-section greater capacity of the cable.
than 16 mm2 (25 mm2 alumin.), the cross-section
of the neutral can be reduced to cross-section/2. The limits for harmonic disturbance
However this reduction is not permitted if: produced by devices are defined in standards
- The loads are not in practice balanced IEC 61000-3-2 (In < 16 A) and IEC 61000-3-12
- The third harmonic (row3) content is greater than 15 %. (16 < In < 75 A)
If this content is greater than 33 %, the cross-section

Reduction factors for harmonics currents in four-core and five-core cables (IEC 60364-5-52)
Reduction factor
Third harmonic content
of phase current Size selection is based Size selection is based
(%) on phase current on neutral current
0 - 15 1.0 -
15 - 33 0.86 -
33 - 45 - 0.86
> 45 - 1.0
DETERMINING THE CROSS-SECTIONS OF CONDUCTORS

Examples of the application of reduction factors for harmonic currents (IEC 60352-5-52)

Consider a three-phase circuit with a design load and a reduction factor of 0,86 is applied, leading
of 39 A to be installed using four-core PVC insulated to a design load of:
cable clipped to a wall, installation method C. 46,8 = 54,4 A
0,86
A 6 mm2 cable with copper conductors has a current- For this load a 10 mm2 cable is suitable.
carrying capacity of 41 A and hence is suitable
if harmonics are not present in the circuit. If 50% third harmonic is present, the cable size is again
selected on the basis of the neutral current, which is:
If 20 % third harmonic is present, then a reduction factor
of 0,86 is applied and the design load becomes: 39 x 0,5 x 3 = 58,5 A
39 = 45 A in this case the rating factor is 1 and a 16 mm2 cable
0,86 is required.
For this load a 10 mm2 cable is necessary.
All the above cable selections are based on the current-
If 40 % third harmonic is present, the cable size selection carrying capacity of the cable; voltage drop and other
is based on the neutral current which is: aspects of design have not been considered.
39 x 0,4 x 3 = 46,8 A

22

EX29008_p16-31.indd 22 30/01/09 15:05:07

 DEVICES FOR PROTECTION AGAINST OVERLOADS
It should be noted that it is possible not to protect
1 LOCATION AND CHOICE a tap-off for a length of 3 metres maximum as long
OF PROTECTION DEVICES as it is created in such a way as to reduce the risk
In principle, a protection device must be placed of short-circuits to the minimum and as long as the
at the origin of each wiring system (main line protection device is placed immediately after this
or tap-off), as soon as the current-carrying capacity Iz 3 metre distance (see p. 04).
of the wiring system becomes lower than the current This provision is particularly useful in the wiring
In of the upstream protection device. of distribution boards.
The protection device must therefore have a rated
current I (rating In, or setting Ir) such that: 3 RECOMMENDATION FOR NO
IB < I < R x IZ (see p. 04) PROTECTION AGAINST OVERLOADS
When called for due to continuity of service or safety,
2 EXEMPTION FROM PROTECTION or if opening the circuit involves danger (smoke clea-
AGAINST OVERLOADS rance motors, circuits of rotating machines, lifting
It is possible to dispense with protection against equipment, etc.) it is not advisable to install any device
overloads in the following cases: with overload protection.
- The wiring system is effectively protected against In this case, the wiring system must be sized for the
overloads by a device upstream overload fault current which may occur: for example,
- The wiring system is not likely to be subject to blocked rotor for a motor.
overloads and has no tap-offs or sockets (devices with
integrated protection that is adapted to the cross-sec-
tion of the cable, fixed device that does not generate
overloads and whose operating current is compatible Only Lexic DX-MA
with the current-carrying capacity of the cable, wiring magnetic circuit
system supplying several tap-offs that are protected breakers comply with
DEVICES FOR PROTECTION AGAINST OVERLOADS

individually and for which the sum of the operating the recommendations
currents is less than the current-carrying capacity for no protection
against overloads.
of the wiring system, wiring systems whose source
cannot supply a current greater than the system's
current-carrying capacity, etc.)
Exemptions cannot be applied to IT systems and in
installations where there is a risk of fire, or without
additional verification.

Caution, this exemption does not concern

short-circuit protection, which must be provi-
ded in all cases. The line in question must not
have any tap-offs. In principle, a line of power
sockets may be subject to overloads and must
always be protected.

23

EX29008_p16-31.indd 23 30/01/09 15:05:07

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Checking voltage It is essential to provide the correct voltage to

drops ensure correct use and quality of the electricity

service. It is therefore important to check that
the cumulative voltage drop from the source up
to any point in the installation does not exceed
the required values.

If the voltage drop is greater than the permitted limits,

it is advisable to increase the cross-section of the Permitted voltage drop limits
conductors until the voltage drop is below the
specified values.
Standard IEC 60364-5-52 recommends a maximum
When the main wiring systems of the installation are value of 4%.
longer than 100 m, the permitted voltage drop limits This value applies to normal operation, and does
can be increased by 0.005% per metre above 100 m, not take account of devices, such as motors, that can
but this additional amount must not itself exceed 0.5%. generate high inrush currents and voltage drops.
More restrictive values may be required for the link
between the transformer and the main breaking
or protection device.
Calculating voltage drops

⎛ ⎞
u = b ⎜ρ1 L cosϕ + λ × L × sinϕ⎟ IB Motor power supplies
⎝ S ⎠
u: voltage drop in V If the installation supplies motors, it is advisable
b: factor: value 1 for three-phase circuits, to check the voltage drop under starting conditions.
and 2 for single phase circuits To do this, simply replace current IB in the formula
ρ1: resistivity of the conductors in Omm2/m (0.023 opposite with the starting current of the motor and
for copper and 0.037 for aluminium) use the power factor on starting. In the absence of
L: length of the wiring system in m more accurate data, the starting current can be taken
S: cross-section of the wiring system in mm2 as being 6 x In. The voltage drop, taking account of all
λ: linear reactance of the conductors in mO/m the motors that may start at the same time, must not
(0.08 for multi-core or single-core cables in trefoil exceed 15%. Apart from the fact that too high a voltage
arrangement, drop can hinder other users of the installation, it may
0.09 for single-core cables touching in flat layers
also prevent the motor starting.
and 0.13 for separate single-core cables)
Cos ϕ: power factor (0.8 in the absence of information)
IB: operating current of the wiring system in A
CHECKING VOLTAGE DROPS

The relative voltage drop (as a %) is calculated

in the following way: The unit voltage drop v (in volts per ampere
Δu = 100 u and for 100 m), can be determined directly from
U0 the tables on the following pages, according to the:
- Cross-section (in mm2) and type of core (copper
u: voltage drop in V or aluminium)
U0: phase-to-neutral voltage in V - Linear reactance of the conductors, λ (in mΩ/m),
connected with their relative arrangement

24

EX29008_p16-31.indd 24 30/01/09 15:05:07

 - Cos ϕ (1 for heating and lighting, 0.85 for
mixed applications, 0.5 when starting motors).
Multi-core or single-core cables
in trefoil arrangement (λ = 0.08 mO/m)
The voltage drop value for the three-phase
wiring system with length L (in m) along Voltage drop per unit (in V) for 100 m of cable
which the operating current IB (in A) travels Three-phase Cu 100 m Three-phase Al 100 m
Cross-
is then,
section cos ϕ cos ϕ
- Expressed in volts:
mm2
1 0.85 0.35 1 0.85 0.35
u = v × IB × L 1.5 1.533 1.308 0.544 2.467 2.101 0.871
100
2.5 0.920 0.786 0.329 1.480 1.262 0.525
- Expressed as a percentage:
4 0.575 0.493 0.209 0.925 0.790 0.331

Δu = v × IB × L 6 0.383 0.330 0.142 0.617 0.528 0.223

U0 0.230 0.200 0.088 0.370 0.319 0.137
10
U0 = 230 V in 400 V three-phase supply.
16 0.144 0.126 0.058 0.231 0.201 0.088
For single phase wiring systems, the u and 25 0.092 0.082 0.040 0.148 0.130 0.059
Δu values must be multiplied by 2 (drop in
35 0.066 0.060 0.030 0.106 0.094 0.044
“the outgoing conductor” and in the “return
conductor” with the same current travelling 50 0.046 0.043 0.024 0.074 0.067 0.033
along both). 70 0.033 0.032 0.019 0.053 0.049 0.026
95 0.024 0.025 0.016 0.039 0.037 0.021
120 0.019 0.021 0.014 0.031 0.030 0.018
150 0.015 0.017 0.013 0.025 0.025 0.016
185 0.012 0.015 0.012 0.020 0.021 0.014
240 0.010 0.012 0.011 0.015 0.017 0.013
300 0.008 0.011 0.010 0.012 0.015 0.012
Example 400 0.006 0.009 0.010 0.009 0.012 0.011
500 0.005 0.008 0.009 0.007 0.011 0.010
In the example on page 54, the precise
calculation of the voltage drop for the 630 0.004 0.007 0.009 0.006 0.009 0.010
“Outgoing 2” cable gives a result of 4.04 V, 2 x 120 0.010 0.010 0.007 0.015 0.015 0.009
i.e. a relative voltage drop of 1.75%.
An identical result is obtained using the 2 x 150 0.008 0.009 0.006 0.012 0.013 0.008
tables. Reading from the table opposite
CHECKING VOLTAGE DROPS

2 x 185 0.006 0.007 0.006 0.010 0.011 0.007

for a copper phase cross-section of 70 mm2
2 x 140 0.005 0.006 0.005 0.008 0.009 0.006
and a cos ϕ of 0.85 gives a value of 0.032.
This value is given for 100 m of cable and 3 x 120 0.006 0.007 0.005 0.010 0.010 0.006
for a current of 1 A. This value must then be 3 x 150 0.005 0.006 0.004 0.008 0.008 0.005
multiplied by 250 (IB = 250 A) and by
0.5 (50 m of cable), which gives an absolute 3 x 185 0.004 0.005 0.004 0.007 0.007 0.005
voltage drop of 4 V and a relative voltage 3 x 240 0.003 0.004 0.004 0.005 0.006 0.004
drop of 1.73%.
4 x 185 0.003 0.004 0.003 0.005 0.005 0.004
4 x 240 0.002 0.003 0.003 0.004 0.004 0.003

25

EX29008_p16-31.indd 25 30/01/09 15:05:07

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Checking voltage
drops (continued)
Single-core cables touching in flat layers (λ = 0.09 mO/m)
Voltage drop per unit (in V) for 100 m of cable
Three-phase Cu 100 m Three-phase Al 100 m
Cross-
section cos ϕ cos ϕ
mm2
1 0.85 0.35 1 0.85 0.35
1.5 1.533 1.308 0.544 2.467 2.101 0.872
2.5 0.920 0.787 0.330 1.480 1.263 0.526
4 0.575 0.493 0.210 0.925 0.791 0.332
6 0.383 0.331 0.143 0.617 0.529 0.224
10 0.230 0.200 0.089 0.370 0.319 0.138
16 0.144 0.127 0.059 0.231 0.201 0.089
25 0.092 0.083 0.041 0.148 0.131 0.060
35 0.066 0.061 0.031 0.106 0.095 0.045
50 0.046 0.044 0.025 0.074 0.068 0.034
70 0.033 0.033 0.020 0.053 0.050 0.027
95 0.024 0.025 0.017 0.039 0.038 0.022
120 0.019 0.021 0.015 0.031 0.031 0.019
150 0.015 0.018 0.014 0.025 0.026 0.017
185 0.012 0.015 0.013 0.020 0.022 0.015
240 0.010 0.013 0.012 0.015 0.018 0.014
300 0.008 0.011 0.011 0.012 0.015 0.013
400 0.006 0.010 0.010 0.009 0.013 0.012
500 0.005 0.009 0.010 0.007 0.011 0.011
630 0.004 0.008 0.010 0.006 0.010 0.010
2 x 120 0.010 0.011 0.008 0.015 0.015 0.010
2 x 150 0.008 0.009 0.007 0.012 0.013 0.009
CHECKING VOLTAGE DROPS

2 x 185 0.006 0.008 0.006 0.010 0.011 0.008

2 x 240 0.005 0.006 0.006 0.008 0.009 0.007
3 x 120 0.006 0.007 0.005 0.010 0.010 0.006
3 x 150 0.005 0.006 0.005 0.008 0.009 0.006
3 x 185 0.004 0.005 0.004 0.007 0.007 0.005
3 x 240 0.003 0.004 0.004 0.005 0.006 0.005
4 x 185 0.003 0.004 0.003 0.005 0.005 0.004
4 x 240 0.002 0.003 0.003 0.004 0.004 0.003

26

EX29008_p16-31.indd 26 30/01/09 15:05:07

 Separate single-core cables (λ = 0.13 mO/m)
Voltage drop per unit (in V) for 100 m of cable
Three-phase Cu 100 m Three-phase Al 100 m
Cross-
section cos ϕ cos ϕ
mm2
1 0.85 0.35 1 0.85 0.35
1.5 1.533 1.310 0.549 2.467 2.104 0.876
2.5 0.920 0.789 0.334 1.480 1.265 0.530
4 0.575 0.496 0.213 0.925 0.793 0.336
6 0.383 0.333 0.146 0.617 0.531 0.228
10 0.230 0.202 0.093 0.370 0.321 0.142
16 0.144 0.129 0.062 0.231 0.203 0.093
25 0.092 0.085 0.044 0.148 0.133 0.064
35 0.066 0.063 0.035 0.106 0.097 0.049
50 0.046 0.046 0.028 0.074 0.070 0.038
70 0.033 0.035 0.024 0.053 0.052 0.031
95 0.024 0.027 0.021 0.039 0.034 0.026
120 0.019 0.023 0.019 0.031 0.033 0.023
150 0.015 0.020 0.018 0.025 0.028 0.021
185 0.012 0.017 0.017 0.020 0.024 0.019
240 0.010 0.015 0.016 0.015 0.020 0.018
300 0.008 0.013 0.015 0.012 0.017 0.016
400 0.006 0.012 0.014 0.009 0.015 0.015
500 0.005 0.011 0.014 0.007 0.013 0.015
630 0.004 0.010 0.013 0.006 0.012 0.014
2 x 120 0.010 0.012 0.009 0.015 0.017 0.011
2 x 150 0.008 0.010 0.009 0.012 0.014 0.010
CHECKING VOLTAGE DROPS

2 x 185 0.006 0.009 0.008 0.010 0.012 0.010

2 x 240 0.005 0.007 0.008 0.008 0.010 0.009
3 x 120 0.006 0.008 0.006 0.010 0.011 0.008
3 x 150 0.005 0.007 0.006 0.008 0.009 0.007
3 x 185 0.004 0.006 0.006 0.007 0.008 0.006
3 x 240 0.003 0.005 0.005 0.005 0.007 0.006
4 x 185 0.003 0.004 0.004 0.005 0.006 0.005
4 x 240 0.002 0.004 0.004 0.004 0.005 0.004

27

EX29008_p16-31.indd 27 30/01/09 15:05:07

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

To guard against the risks of short-circuit

currents, all short-circuit protection devices
must comply with the following two rules:
Protection against - The breaking capacity of the device must
be at least equal to the maximum prospective
short-circuit current at its installation point
short-circuits - The breaking time, for a short-circuit
occurring at any point in the installation,
must not be greater than the time taken
for the temperature of the conductors
to reach the maximum permissible value.

When applying these rules, it is necessary to As a general rule the short-circuit protection must
determine the maximum short-circuit current be placed at the supply end of each circuit.
for each circuit at its origin and the minimum For the standards and exceptions, see p. 04.
short-circuit current at its end.
The maximum short-circuit current at the origin
of the circuit is used to:
- Determine the necessary breaking capacity
of the protection devices
- Check the protection of the conductors against
thermal stresses
The minimum short-circuit current at the end
of the circuit is used to:
- Check the breaking conditions for the magnetic
setting of the circuit breakers
- Check the protection of the conductors
against thermal stresses in particular in the event < Adjusting the magnetic
of protection using fuses or time-delayed threshold of a DPX
circuit breakers. circuit breaker

BREAKING CAPACITY
The breaking capacity of a protection device must be
at least equal to the maximum prospective short- Back up or coordination
circuit current which may occur at the point at which of protection devices
this device is installed.
Breaking capacity < Ikmax The breaking capacity of the protection device can,
The maximum prospective short-circuit current to be by special dispensation, be lower than the maximum
prospective short-circuit provided that:
taken into account is:
- The device is combined with a device upstream that
- The symetrical three-phase short-circuit current Ik3,
has the necessary breaking capacity
for three-phase circuits (3 phases or 3 phases - The downstream device and the protected wiring
+ neutral) systems can withstand the power limited by the
BREAKING CAPACITY

- The two-phase short-circuit current Ik2, for combination of the devices.

two-phase circuits (phase/phase) For the characteristics of DX and DPX devices used
- The single phase short-circuit current Ik1 for single in combination see the “Breaking and protection
phase circuits (phase/neutral) devices” book.
For details of how to estimate Ik values, see p. 46.

28

EX29008_p16-31.indd 28 30/01/09 15:05:07

 Special case of the IT system in France

Article 533.3 of standard NF C 15-100 indicates that when - 0.25 times the three-phase short-circuit current
an IT system is used for an installation, the breaking at the installation point if it is greater than 10 kA
capacity rule must be applied for the three-phase short- Example: in a 230/400 V installation, for a 20 kA
circuit and also for the prospective double fault current. three-phase short-circuit current, the protection devices
By convention, the protection device must be able to must be able to break 0.25 x 20 = 5 kA, at 400 V and
break the double fault current at the phase-to-phase on a single pole.
voltage and on a single pole. The double fault current For the characteristics of Legrand circuit breakers
is taken as being: in IT systems, see the “Breaking and protection
- 0.15 times the three-phase short-circuit current at the devices” book.
installation point if it is less than or equal to 10 kA

CHECKING THE THERMAL STRESSES PERMITTED

BY CONDUCTORS
Following a short-circuit that takes place at any point The maximum thermal stress (for times of less than
on a circuit, the breaking time of a circuit breaker 5 s) that a wiring system can withstand is calculated

CHECKING THE THERMAL STRESSES PERMITTED BY CONDUCTORS

must not be longer than the time taken for the tempe- using the following formula:
rature of the conductors to reach the permissible limit I2t = K2 x S2
θ° max. in the table below. In practice, it is advisable
to check that the energy which the circuit breaker
allows to pass is not greater than that which the cable
can actually withstand.

Value of K for live and protective conductors

PVC XLPE/EPR Rubber Rubber Silicone No
Insulation material
60°C 85°C rubber insulation

θ°max (°C) 160/140(2) 250 200 220 350 200/150(1)

Copper 143/133(2) 176 159 166 201 159/138(1)

Protective conductor not
incorporated in a cable or Aluminium 95/88(2) 116 105 110 133 105/91(1)
conductors not grouped together
Steel 52/49(2) 64 58 60 73 58/50(1)

Copper 115/103(2) 143 141 134 132 138

Live or protective conductor as
part of a multi-core cable or Aluminium 76/68(2) 94 93 89 87 91
conductors grouped together
Steel 50

(1) If there is a particular fire risk

(2) Cross-section greater than 300 mm2 or conductors grouped together
29

EX29008_p16-31.indd 29 30/01/09 15:05:08

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against
short-circuits (continued)
1 LIVE CONDUCTORS 1.2 Fuse protection
In the case of fuse protection, it is necessary to check
1.1 Protection using circuit breaker that the smallest short-circuit value at the end of the
installation will cause the fuse to “blow” within a time
In the case of protection using a circuit breaker,
that is compatible with the thermal stress of the cable.
it is advisable to check that the energy which the
Caution: the short-circuit currents to be taken into
device allows to pass remains below the maximum
account are those at the end of the wiring system:
stress permitted by the wiring systems.
- Ik1 for circuits with distributed neutral
The current to be taken into account is the maximum
- Ik2 for circuits without distributed neutral
short-circuit current at the origin of the circuit
in question:
- Ik3 for three-phase circuits (3 phases or 3 phases Curve showing
+ neutral) Time operation
of fuse
- Ik2 for two-phase circuits
- Ik1 for single phase circuits (phase + neutral).
It is possible to check that the limit value is actually Curve showing
The minimum
t conductor
below that which the conductors can withstand current/time short-circuit
for the prospective fault conditions by directly current value must
reading from the thermal stress limitation curves be greater than
for circuit breakers. value Ia
Ia Current
CHECKING THE THERMAL STRESSES PERMITTED BY CONDUCTORS

Thermal Curve showing

stress: Izt thermal stress
that cable will
withstand Maximum thermal stress values in cables (in A 2s)
according to their type and cross-section
Curve showing
thermal stress S (mm2) Cu/PVC Cu/PR Al/PVC Al/PR
limited by circuit
breaker 1.5 2.98 ·104 4.6 ·104
2.5 8.27 ·104 1.28 ·105
Isc
Thermal Magnetic 4 2.12 ·105 3.27 ·105
6 4.76 ·105 7.36 ·105
10 1.32 ·106 2.04 ·106 5.78 ·105 8.84 ·105
16 3.39 ·106 5.23 ·106 1.48 ·106 2.26 ·106
25 8.27 ·106 1.28 ·107 3.61·105 5.52 ·105
In the case of circuit breakers on which the
35 1.62 ·107 2.51 ·107 7.08 ·106 1.08 ·107
magnetic release is delayed, the thermal
stresses must be systematically checked. 50 3.31 ·107 5.11 ·107 1.44 ·107 2.21 ·107
It is not generally necessary to do this for live 95 1.19 ·108 1.85 ·108 5.21 ·107 7.97 ·107
conductors (phase and neutral) if: 120 1.9 ·108 2.94 ·108 8.32 ·107 1.27 ·108
- The protection device, at the origin of the 150 2.98 ·108 4.60 ·108 1.3 ·108 1.99 ·108
wiring system, has an overload protection 185 4.53 ·108 7 ·108 1.98 ·108 3.02 ·108
function 240 7.62 ·108 1.18 ·109 3.33 ·108 5.09 ·108
- The cross-section of the neutral conductor
300 1.19 ·109 1.84 ·109 5.2 ·108 7.95 ·108
is not smaller than that of the phase
400 2.12 ·109 3.27 ·109 9.24 ·108 1.41 ·109
conductors.
500 3.31 ·109 5.11 ·109 1.44 ·109 2.21 ·109

30

EX29008_p16-31.indd 30 30/01/09 15:05:08

 protective conductor, at the end of the circuit
2 PROTECTIVE CONDUCTORS in question, irrespective of the type of protection.
It is not necessary to check the thermal stresses The cross-section is calculated for breaking times
if the cross-section of the protective conductor has of less than 5 s using the following formula:
been selected in accordance with the table below. 2
In TN-C systems, the cross-section of the PEN SPE = I t
conductor must not be less than 10 mm2 for copper K
and 16 mm2 for aluminium. SPE: cross-section of the protective conductor in mm2
If the cross-section of protective conductors is I: rms value of the fault current in A
determined by the calculation, the short-circuit t: operating time of the breaking device
current to be taken into account for checking the K: factor depending on the permissible temperatures,
thermal stress is the minimum fault current (If). In this the metal of which it is made and the insulation mate-
case it is determined between a live conductor and the rial (see actual value in the table on p. 29).

cross-section of the protective conductor (S PE) according to the cross-section

of the phase conductors (Sph)
For equipment with high permanent leakage currents (>10 mA),
Cross-section Cross-section the cross-section SPE of the protective conductor must be
of phase of protective at least 10 mm2 for copper or 16 mm2 for aluminium, or even
conductors Sph conductors SPE twice the“normal” cross-section by the provision of a second
Sph < 16 mm2 Sph
conductor parallel to the first installed up to the point in the
installation where a cross-section of 10 mm2 (copper)

CHECKING THE THERMAL STRESSES PERMITTED BY CONDUCTORS

16 mm2 < Sph < 35 mm2 16 mm2 or 16 mm2 (aluminium) is reached.
Use of the TN system is recommended when there are high
Sph > 35 mm2 5 Sph leakage currents.

Calculating If Calculation of the K factor

The conventional approximate method can K expressed as As0.5/mm2 is calculated using the formula:

( ) ×10
be applied, in view of the distance of the power
supply. The phase/earth fault current If can CV B0 + 20 ⎛ ⎞
be taken (ignoring the reactances) as being: K= −12
× ln ⎜1+ θf − θ1 ⎟
ρ20 ⎝ B0 + θ1 ⎠
If = 0,8 × U0
RPh + RPE where:
CV: thermal capacity per unit volume in J/°C·m3
U0: simple phase/neutral voltage CV = CM x MV
RPh: resistance of the phase conductor CM: specific heat of the conductor in J/°C·kg
RPE: resistance of the protective conductor MV: density in kg/m3
The value 0.8 is based on the hypothesis that the B0: inverse of the resistance factor at 0°C
voltage at the origin of the circuit is 80% of the ρ20: resistance the material at 20°C in Ωm
nominal voltage or that the impedance of the θ1: initial temperature of the conductor in °C
part of the fault loop upstream of the protection θf: final temperature of the conductor in °C
devices represents 20% of the total impedance
of the loop.

31

EX29008_p16-31.indd 31 30/01/09 15:05:08

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against
short-circuits (continued)
CHECKING THE MAXIMUM PROTECTED LENGTHS
A check must be carried out to ensure that the S: cross-section of the conductors, in mm2
smallest short-circuit current will correctly activate ρ: resistivity of the metal constituting the core
the protection device. Do do this, all that is necessary of the conductor, in O mm2/m
is to check that this current at the end of the wiring Ia: tripping current of the circuit breaker, in A
system to be protected is higher than the magnetic trip It is however necessary, for large cross-section cables
threshold of the circuit breaker. The most unfavoura- (≥ 150 mm2), to make a correction in order to take
ble trip value must be taken into account. If there is no account of the effect of their reactance. This is already
manufacturer's data, the upper limits of the standard incorporated in the tables on the following pages.
tripping curves must be used:
- 5 × In for curve B circuit breakers
- 10 × In for curve C circuit breakers
- 20 × In for curve D circuit breakers
For adjustable magnetic devices, the threshold is Correction factors to be applied
increased by a tolerance of 20%. to the conductor lengths given in the tables
A simple calculation method (known as the conven-
tional method) can be used to estimate the maximum • Conductor core
The values are given for copper conductors.
protected lengths according to the magnetic setting of
For aluminium conductors, these values must
the circuit breakers. It is valid for circuits located some
be multiplied by 0.62 for protection using circuit
distance from the source and not supplied by breakers and by 0.41 for protection using fuses.
an alternator.
This method assumes that if there is a short-circuit, • Type of circuit
the voltage at the origin of the faulty circuit is equal The tables are given for 230 V single phase and 400
to 80% of the nominal voltage of the power supply. This V three-phase circuits with neutral. The table below
means that the impedance of the faulty circuit repre- gives the values of the multiplication factors to be
sents 80% of the total impedance of the fault loop. applied in other cases.
This can be expressed by the formula below:
CHECKING THE MAXIMUM PROTECTED LENGTHS

0,8 × U = Zd × Ikmin 400 V three-phase Multiplication correction

or two-phase circuit factor
U: voltage during normal service at the location where
the protection device is installed Without neutral 1.72
Zd: impedance of the fault loop for the part concerning With full neutral 1
the faulty circuit. Twice the length of the circuit must
With half neutral 0.67
be taken into consideration (outgoing and return
current)
Ikmin: minimum short-circuit current
This formula can also be written in the following form:
0,8 × U0 × S
Lmax =
2 × ρ × Ia
The tables on the following pages can be
Lmax: maximum protected length, in m used to determine the maximum lengths of
U0: nominal phase-to-neutral voltage of the instal- protected cable, but under no circumstances
lation, in V. If the neutral is not distributed, use the the current-carrying capacities IZ (see p. 20).
phase-to-phase voltage

32

EX29008_p32.indd 32 3/02/09 12:47:13

 Maximum theoretical lengths (in m) of conductors protected against minimum short-circuits
according to the cross-section of the conductor and the protection device (1)
Circuit breaker rating In (in A)
Circuit S
breaker (mm2)
2 4 6 10 16 20 25 32 40 50 63 80 100 125

1.5 300 150 100 60 38 30 24 19

2.5 500 250 167 100 63 50 40 31 25

4 800 400 267 160 100 80 64 50 40 32

6 600 400 240 150 120 96 75 60 48 38

LR, DX, DX-E
10 667 400 250 200 160 125 100 80 63 50
curve C
16 1067 640 400 320 256 200 160 128 102 80 64

25 1000 625 500 400 313 250 200 159 125 100 80

35 875 700 560 438 350 280 222 175 140 112

50 800 625 500 400 317 250 200 160

1.5 600 300 200 120 75 60 48 38

2.5 1000 500 333 200 125 100 80 63 50

4 1600 800 533 320 200 160 128 100 80 64

6 1200 800 480 300 240 192 150 120 96 76

LR, DX, DX-E
10 1333 800 500 400 320 250 200 160 127 100
curve B
16 2133 1280 800 640 512 400 320 256 203 160 128

25 2000 1250 1000 800 625 500 400 317 250 200 160
CHECKING THE MAXIMUM PROTECTED LENGTHS

35 1750 1400 1120 875 700 560 444 350 280 224

50 1600 1250 1000 800 635 500 400 320

1.5 150 75 50 30 19 15 12 9

2.5 250 125 83 50 31 25 20 16 13

4 400 200 133 80 50 40 32 25 20 16

6 300 200 120 75 60 48 38 30 24 19

DX
10 333 200 125 100 80 63 50 40 32 25
curve D
16 233 320 200 160 128 100 80 64 51 40 32

25 500 313 250 200 156 125 100 79 63 50 40

35 438 350 280 219 175 140 111 88 70 56

50 400 313 250 200 159 125 100 80

(1) Caution: These values are given for copper conductors in 230 V single phase or 400 V three-phase supply networks with neutral
(Sneutral = Sphase). For any other type of conductor or circuit, apply a correction factor (see p. 32)

33

EX29008_p33.indd 33 3/02/09 12:47:53

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against
short-circuits (continued)
Maximum theoretical lengths (in m) of conductors protected against minimum short-circuits
by a DPX according to the cross-section of the conductor and the setting of the DPX (1)
Magnetic setting of the
90 100 125 160 200 250 320 400 500 700 800 875 1000
DPX (Im in A)

1.5 56 50 40 31 25 20 16 13 10 7 6 6 5
Cross-
2.5 93 83 67 52 42 33 26 21 17 12 10 10 8
section of
conductor 4 148 133 107 83 67 53 42 33 27 19 17 15 13
(S in mm2) 6 222 200 160 125 100 80 63 50 40 29 25 23 20
10 370 333 267 208 167 133 104 83 67 48 42 38 33
16 593 533 427 333 267 213 167 133 107 76 67 61 53
25 667 521 417 333 260 208 167 119 104 95 83
35 583 467 365 292 233 167 146 133 117
50 667 521 417 333 238 208 190 167
70 729 583 467 333 292 267 233
95 452 396 362 317
120 500 457 400
150 497 435
185 514

Magnetic setting of the

1120 1250 1600 2000 2500 3200 4000 5000 6300 8000 12,500 16,000
DPX (Im in A)

1.5 4 4 5
Cross-
2.5 7 7 5 4 3 3
section of
conductor 4 12 11 8 7 5 4 3 3
CHECKING THE MAXIMUM PROTECTED LENGTHS

(S in mm2) 6 18 16 13 10 8 6 5 4 3
10 30 27 21 17 13 10 8 7 5 4
16 48 43 33 27 21 17 13 11 8 7 4 3
25 74 67 52 42 33 26 21 17 13 10 7 5
35 104 93 73 58 47 36 29 23 19 15 9 7
50 149 133 104 83 67 52 42 33 26 21 13 10
70 208 187 146 117 93 73 58 47 37 29 19 15
95 283 253 198 158 127 99 79 63 50 40 25 20
120 357 320 250 200 160 125 100 80 63 50 32 25
150 388 348 272 217 174 136 109 87 69 54 35 27
185 459 411 321 257 206 161 128 103 82 64 41 32
240 571 512 400 320 256 200 160 128 102 80 51 40
300 500 400 320 250 200 160 127 100 64 50

(1) Caution: These values are given for copper conductors in 230 V single phase or 400 V three-phase supply networks
34 with neutral (Sneutral = Sphase). For any other type of conductor or circuit, apply a correction factor (see p. 32)

EX29008_p34.indd 34 3/02/09 12:48:10

 Maximum theoretical lengths (in m) of conductors protected against minimum short-circuits
by fuses according to the cross-section of the conductor and the type of fuse (1)
S Rated current of PVC/XLPE aM fuses (in A)
(mm2) 16 20 25 32 40 50 63 80 100 125 160 200 250 315 400 500 630 800 1000 1250
1.5 28/33 19/23 13/15 8/10 6/7
2.5 67 47/54 32/38 20/24 14/16 9/11 6/7
4 108 86 69 47/54 32/38 22/25 14/17 9/11 6/7
6 161 129 104 81 65/66 45/52 29/34 19/23 13/15 9/10 6/7
10 135 108 88 68 47/54 32/38 21/25 14/16 9/11 6/7
16 140 109 86 69 49/55 32/38 21/25 14/17 9/11 6/7
25 135 108 86 67 47/64 32/38 21/25 14/16 9/11
35 151 121 94 75 58/60 38/45 25/30 17/20 11/13 7/9
50 128 102 82 65 43/51 29/36 19/24 13/15 8/10
70 151 121 96 75 56/60 38/45 26/30 17/20 11/13
95 205 164 130 102 82 65 43/51 29/34 19/23
120 164 129 104 82 65 44/52 29/35
150 138 110 88 69 55 37/44
185 128 102 80 64 61
240 123 97 78 62

S Rated current of PVC/XLPE gG fuses (in A)

(mm2)
16 20 25 32 40 50 63 80 100 125 160 200 250 315 400 500 630 800 1000 1250
1.5 82 59/61 38/47 18/22 13/16 6/7
2.5 102 82 49/56 35/43 16/20 12/15 5/7
CHECKING THE MAXIMUM PROTECTED LENGTHS

4 131 89 76 42/52 31/39 14/17 8/10 4/5

6 134 113 78 67/74 31/39 18/23 10/12 7/9
10 189 129 112 74 51/57 27/34 19/24 19/12 7/9 3/4
16 179 119 91 67 49/56 24/30 18/23 9/11 5/7 3/4
25 186 143 104 88 59/61 45/53 22/27 13/16 7/9 4/5
35 200 146 123 86 75 43/52 25/36 14/18 8/11 4/5
50 198 167 117 101 71 45/54 26/33 16/22 8/11 5/7
70 246 172 150 104 80 57/60 34/42 17/22 11/14
95 233 203 141 109 82 62 32/40 20/25 9/11
120 256 179 137 103 80 51/57 32/40 14/18
150 272 190 145 110 85 61 42/48 20/24
185 220 169 127 98 70 56 27/34
240 205 155 119 85 68 43/46

(1) Caution: These values are given for copper conductors in 230 V single phase or 400 V three-phase supply networks with neutral
(Sneutral = Sphase). For any other type of conductor or circuit, apply a correction factor (see p. 32) 35

EX29008_p35.indd 35 3/02/09 12:48:23

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against All electrical installations must be protected

against indirect contact. Various methods

indirect contact described in the book “Electrical danger

and the protection of people” can be used
to provide this protection. This section defines
the protection conditions involving automatic
disconnection of the power supply.

The standard specifies that the fault current If must

be eliminated within a time that is compatible with Limit voltage
the safety of people.
This time is determined by reading the curves (see the The limit voltage
book “Electrical danger and the protection of people”) represents the value
defined according to the prospective touch voltage Uc. of the threshold below
These curves have been presented in the form which there is no risk
of tables giving the maximum breaking time according of electrocution.
to the selected earthing system, the nominal voltage As a general rule,
of the installation and the limit voltage. the nominal voltage
More often than not in TT systems, the presence of installations is higher
of residual current devices enables this verification than the limit voltage
(50 V). To ensure
to be dispensed with. The residual current device must
there is no danger,
be sized according to the value of the earth connection
the prospective touch
and the type of use. voltage UC must remain
In principle, it is necessary to calculate the fault below the limit voltage.
current values and comply with the maximum
breaking times.

TT SYSTEM
In this neutral earthing system, protection is more
often than not based on the use of residual current Maximum breaking time in TT systems
devices. The impedance of the fault loop is high
(two earthing resistances) and the intensity of the fault Breaking time t0 (s)
Nominal voltage UL: 50 V
current is too low to activate the overcurrent of the power supply U0 (V)
protection devices. AC DC
The maximum sensitivity of the residual current (1)
50 < U0 < 120 0.3
devices must be selected so that the touch voltage
does not exceed the limit voltage UL (50 V in the 120 < U0 < 230 0.2 0.4
formula below). 230 < U0 < 400 0.07 0.2

I n 50 U0 < 400 0.04 0.1

RA
(1) A breaking time may be specified for reasons other
IΔn: sensitivity of the residual current device than protection against electric shocks
TT SYSTEM

RA: resistance of the earth connection of the exposed

conductive parts in use.

36

EX29008_p36.indd 36 3/02/09 12:48:37

 TN SYSTEM
In the TN system, protection against indirect contact
is provided by overcurrent protection devices. In practice, when the circuit is protected by
It is essential to check that the fault current is high a circuit breaker, it is not necessary to check
enough to activate these devices and that this occurs the breaking time rule. However, if a time-
within a short enough time. delayed circuit breaker is used, a check must
be carried out to ensure that the total breaking
time of the device (time delay + opening of the
1 BREAKING TIME contacts) remains compatible with the
specified times.
A conventional breaking time of no more than 5 s
is permitted for distribution circuits and for terminal
circuits with a rated current greater than 32 A.
For terminal circuits with a rated current In < 32 A,
the breaking times of the protection devices must not 2 FAULT CURRENT
exceed the values in the table below:
The principle of protection is based on the fact
that an insulation fault in a TN system is converted
Maximum breaking time in TN systems to a phase/neutral short-circuit. If the fault current
is high enough, the protection is then provided
Breaking time t0 (s) by the overcurrent protection devices.
Nominal voltage of the power UL: 50 V This is expressed by the following rule:
supply U0 (V)
AC DC U0
If Ia
50 < U0 < 120 0.8 (1) ZS

120 < U0 < 230 0.4 5 U0 = nominal phase-to-neutral voltage of the

installation
230 < U0 < 400 0.2 0.4
ZS = total impedance of the fault loop
U0 < 400 0.1 0.1 Ia = current ensuring operation of the protection device
(1) A breaking time may be specified for reasons other within the required time.
than protection against electric shocks

In Belgium, above 400 V, the safety curves are given

in the national requirements. Fault loop in TN systems
In the Netherlands, the maximum breaking time given
in the table applies to all circuits supplying power L1

socket outlets and for other terminal circuits L2

up to 32 A. L3

In China, the maximum breaking time given in the PEN

table applies to terminal circuits supplying portable
or mobile equipment. If
TN SYSTEM

37

EX29008_p37.indd 37 3/02/09 12:48:47

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against
indirect contact (continued)
Protection using fuses
A check must be carried out to ensure t
that the fault current correctly blows the fuse
within the required time. This condition is verified 5s
if t1, the blowing time of the fuse for the calculated
fault current If, is shorter than time t0, the breaking t0
time specified by the standard.
t1

If t1 < t0 then protection is ensured

If I

Protection using circuit breakers

When using circuit breakers for protection, t
a check must be carried out to ensure
that the fault current is higher than the magnetic
Im: magnetic tripping current
trip threshold of the circuit breaker. If: fault current
t0
The most unfavourable trip value must be taken t1: circuit breaker operating time
into account. With DPX, this is the setting value t0: maximum breaking time
of the magnetic relay plus the operating tolerance (see table)
(20% for thermal-magnetic devices and 10%
t1
If If > Im + 20% and t1 < t0 then
for electronic devices). In the case of DX modular protection is ensured
circuit breakers, it is the maximum value
of the tripping range: Im If I
(= Ia)
4 x In for curve B
9 x In for curve C
14 x In for curve D

3 MAXIMUM PROTECTED LENGTHS

In practice, it is not necessary to know the fault
current If in order to determine the maximum length
of protected wiring system. This length is estimated
according to the magnetic tripping current Im (or Ia)
of the protection devices (see p. 32).
TN SYSTEM

38

EX29008_p38.indd 38 3/02/09 12:49:01

 IT SYSTEM
1 ON THE FIRST FAULT Second fault, interconnected exposed
The advantage of the IT system is that it does not trip conductive parts
on the first fault. Due to the high loop impedance in the
L1
event of a first fault, the fault current which circulates
L2
in the installation is low and the touch voltage remains L3
considerably below the limit voltage. There is therefore N
no risk for users. The presence of this fault must be PE
indicated by the permanent insulation monitoring (PIM). CPI Z

Idf

First fault in IT systems RB

L1
L2
L3
N If the exposed conductive parts are interconnected,
PE the double fault current is similar to a short-circuit
CPI Z
and is no longer limited by the earth connections.
If As in a TN system, a check must be carried out to
RB
ensure that the double fault current is high enough
to activate the overcurrent protection devices. The TN
system protection rules can then be applied, taking
account of the phase or phase-to-phase voltage
(distributed or non-distributed neutral) and a loop
impedance incorporating the path of the double
2 ON THE SECOND FAULT fault current.
When a second fault occurs, the power supply must This can be expressed by the following rule:
be disconnected. There are two possibilities,
Idf U' Ia
depending on the way the exposed conductive parts
2 ZS
are connected.
1 - The exposed conductive parts of the receivers Idf: double fault current
are all interconnected via the PE conductor U’: phase-to-phase voltage if the neutral is not dis-
(recommended configuration): the conditions tributed; phase-to-neutral voltage if the neutral is
to be applied are those of the TN system. distributed
2 - The exposed conductive parts are not interconnec- ZS: total impedance of the fault loop
ted and are connected to separate earth connections: Ia: current ensuring operation of the protection device
the conditions to be applied are those of the TT system. within the required time.
IT SYSTEM

39

EX29008_p39.indd 39 3/02/09 12:49:14

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against
indirect contact (continued)
Maximum breaking time according Second fault, separate exposed conductive parts
to the supply voltage L1
Breaking time t0 (s) L2
Nominal voltage for UL: 50 V L3
U0/Un (V) N
Non-distributed Distributed
neutral neutral PE
CPI Z
120/240, 127/230 0.8 5

220/380, 230/400 0.4 0.8

400/690 0.2 0.4

RB RA
If the exposed conductive parts are not interconnected
and two faults occur on circuits connected to separate
earth connections, the double fault current loops via
earth and is limited by two earth connections. When the exposed conductive parts on the low
The value of the fault current may be too low voltage side of the transformer station are not
to activate the overcurrent protection devices but may connected to the other exposed conductive
nevertheless generate a dangerous touch voltage. parts in the installation, a residual current
The standard then requires residual current devices device must be installed at the origin of the
installation. The same applies when the earth
to be installed on each group of exposed conductive
connection of the voltage surge limiter is not
parts. They are selected in the same way as for TT connected to all the interconnected exposed
systems. conductive parts.

CHECKING THE MAXIMUM PROTECTED LENGTHS

CHECKING THE MAXIMUM PROTECTED LENGTHS

All that is necessary is to verify that the fault current This method assumes that if there is a short-circuit,
is higher than the magnetic trip threshold of the circuit the voltage at the origin of the faulty circuit is equal
breaker and to take the most unfavourable trip value to 80% of the nominal voltage of the installation. This
into account: means that the impedance of the faulty outgoing line
- Upper limit of tripping curves B (4 x In), C (9 x In) represents 80% of the total impedance of the fault loop.
or D (14 x In) for DX circuit breakers This can be expressed by the general formula:
- Magnetic setting value plus the operating tolerance
of 20% for DPX thermal-magnetic circuit breakers 0,8 U0 R a R PE If
and 10 % for electronic DPX devices.
As when estimating the maximum lengths protected U0: phase-to-neutral voltage (in V)
against minimum short-circuits, a simple calculation RPE: resistance of the protective conductor of the faulty
method (known as the conventional method) can be circuit
used to verify the maximum lengths for circuits that Ra: resistance of a live conductor of the faulty circuit
are some distance from the source (secondary and If: fault current between phase and exposed conductive
terminal circuits) and not supplied by an alternator. part.

40

EX29008_p40.indd 40 3/02/09 12:49:24

 This formula can also be written in the following form
(TN system): IT system
0,8 U0 Sph
Lmax In the case of IT systems with interconnected exposed
1 m Ia
conductive parts, the fault current is in fact a double
fault current. Since it is impossible to define which
Lmax: maximum protected length (in m) circuit will be the second faulty circuit, it is assumed
U0: phase-to-neutral voltage (in V) that it will have the same characteristics as the circuit
Sph: cross-section of a phase conductor in the faulty being studied. The formula opposite becomes:
circuit, in mm2
1 0,8 U ' Sph
m: Sph/SPE, ratio of the cross-section of the phase Lmax
conductor over that of the protective conductor 2 1 m Ia
ρ: resistivity of the metal constituting the core of the Lmax: maximum protected length (in m)
conductor (in Ω mm2/m), 0.0225 for copper and 0.035 U’: phase-to-phase voltage if the neutral is not dis-
for aluminium tributed; phase-to-neutral voltage if the neutral is
Ia: tripping current of the circuit breaker distributed (in V)
Sa: cross-section of a live conductor in the faulty circuit
The tables on the following pages can be used to (in mm2), phase conductor if the neutral is not distribu-
determine the maximum protected lengths according ted and neutral conductor if the neutral is distributed
to the type of protection and the type of conductor core. m: Sa/SPE, ratio of the cross-section of the live
These values are given for circuits in which the cross- conductor over that of the protective conductor
section of the PE is equal to the cross-section of the ρ: resistivity of the metal constituting the core
phases. If the PE is smaller, the values must be multi- of the conductor (in Ω mm2/m)
plied by the factors in the table opposite. Ia: tripping current of the circuit breaker
The corrections connected with the effect of the reac- If the neutral is distributed and its cross-section
tance of large cross-section conductors (≥ 150 mm2) is smaller than those of the phase conductors,
are incorporated directly in the tables. the tables must be read referring to the actual
(smaller) cross-section of the neutral conductor. CHECKING THE MAXIMUM PROTECTED LENGTHS

Correction factors to be applied to the maximum protected theoretical lengths

according to the neutral earthing system and the cross-section of the protective conductor
Copper conductors Aluminium conductors

m = SPE/Sph 1 0.5 0.33 0.25 0.2 1 0.5 0.33 0.25 0.2

TN 230/400 V 1 0.67 0.5 0.4 0.33 0.62 0.41 0.31 0.25 0.20

IT 400 V
non-distributed 0.86 0.58 0.43 0.34 0.28 0.53 0.34 0.26 0.21 0.17
neutral
IT 230/400 V
0.5 0.33 0.25 0.2 0.16 0.31 0.20 0.15 0.12 0.1
distributed neutral

41

EX29008_p41.indd 41 3/02/09 12:49:44

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against
indirect contact (continued)
The following tables can be used to Example
determine the maximum lengths
of protected cable, but under A wiring system protected by a DPX 250 ER with:
no circumstances the current- - Length of busbar: 75 m
carrying capacities IZ (see p. 06). - Cross-section of the phase conductors: 70 mm2
The values are given for copper - Cross-section of the PE conductor: 35 mm2
conductors in 230 V single phase - Magnetic setting of the circuit breaker: Im = 2500 A
or 400 V three-phase supply Reading from the table for DPX circuit breakers on the next page
networks with neutral (Sneutral gives a maximum protected length of 93 m.
= Sphase). For any other type of As ratio m (SPE/Sph) is 0.5, in TN systems a correction factor of 0.67
conductor or circuit, apply a must be applied (see table on p. 41). The length that is actually
correction factor (see p. 41). protected is therefore 62 m (93 x 0.67), and is not compatible
with the actual length of the cable, which is 75 m.

Maximum theoretical lengths (in m) of conductors protected against indirect contact by modular
circuit breaker according to the cross-section of the conductor and the protection device
Circuit S Circuit breaker rating In (in A)
breaker (mm2) 2 4 6 10 16 20 25 32 40 50 63 80 100 125
1.5 600 300 200 120 75 60 48 35
2.5 1000 500 333 200 125 100 80 63 50
4 1600 800 533 320 200 160 128 100 80 64
6 1200 800 480 300 240 192 150 120 96 76
LR, DX-E, DX
10 1333 800 500 400 320 250 200 160 127 100
curve B
16 2133 1280 800 640 512 400 320 256 203 160 128
25 200 1250 1000 800 625 500 400 317 250 100 160
35 1750 1400 1120 875 700 560 444 350 280 224
50 1660 1250 1000 800 635 500 400 320
1.5 300 150 100 60 38 30 24 19
CHECKING THE MAXIMUM PROTECTED LENGTHS

2.5 500 250 167 100 63 50 40 31 25

4 800 400 267 160 100 80 64 50 40 32
6 600 400 240 150 120 96 75 60 48 38
LR, DX-E, DX
10 667 400 250 200 160 125 100 80 63 50
curve C
16 1067 640 400 320 256 200 160 128 102 80 64
25 1000 625 500 400 313 250 200 159 125 100 80
35 875 700 560 438 350 280 222 175 140 112
50 800 625 500 400 317 250 200 160
1.5 150 75 50 30 19 15 12 9
2.5 250 125 83 50 31 25 20 16 13
4 400 200 133 80 50 40 32 25 20 16
6 300 200 120 75 60 48 38 30 24 19
DX
10 333 200 125 100 80 63 50 40 32 25
curve D
16 233 320 200 160 128 100 80 64 51 40 32
25 500 313 250 200 156 125 100 79 63 50 40
35 438 350 280 219 175 140 111 88 70 56
50 400 313 250 200 159 125 100 80

42

EX29008_p42.indd 42 3/02/09 12:49:56

 Maximum theoretical lengths (in m) of conductors protected against indirect contact by DPX circuit
breaker according to the cross-section of the conductor and the setting of the DPX
Magnetic setting of
90 100 125 160 200 250 320 400 500 700 800 875 1000
the DPX (Im in A)
1.5 56 50 40 31 25 20 16 13 10 7 6 6 5
Cross-section
of conductor 2.5 93 83 67 52 42 33 26 21 17 12 10 10 8
(S in mm2) 4 148 133 107 83 67 53 42 33 27 19 17 15 13
6 222 200 160 125 100 80 63 50 40 29 25 23 20
10 370 333 267 208 167 133 104 83 67 48 42 38 33
16 593 533 427 333 267 213 167 133 107 76 67 61 53
25 667 521 417 333 260 208 167 119 104 95 83
35 583 467 365 292 233 167 146 133 117
50 667 521 417 333 238 208 190 167
70 729 583 467 333 292 267 233
95 452 396 362 317
120 500 457 400
150 497 435
185 514

Magnetic setting of
1120 1250 1600 2000 2500 3200 4000 5000 6300 8000 12500 16000
the DPX (Im in A)
1.5 4 4 5
Cross-section
of conductor 2.5 7 7 5 4 3 3
CHECKING THE MAXIMUM PROTECTED LENGTHS

(S in mm2) 4 12 11 8 7 5 4 3 3
6 18 16 13 10 8 6 5 4 3
10 30 27 21 17 13 10 8 7 5 4
16 48 43 33 27 21 17 13 11 8 7 4 3
25 74 67 52 42 33 26 21 17 13 10 7 5
35 104 93 73 58 47 36 29 23 19 15 9 7
50 149 133 104 83 67 52 42 33 26 21 13 10
70 208 187 146 117 93 73 58 47 37 29 19 15
95 283 253 198 158 127 99 79 63 50 40 25 20
120 357 320 250 200 160 125 100 80 63 50 32 25
150 388 348 272 217 174 136 109 87 69 54 35 27
185 459 411 321 257 206 161 128 103 82 64 41 32
240 571 512 400 320 256 200 160 128 102 80 51 40
300 500 400 320 250 200 160 127 100 64 50

43

EX29008_p43.indd 43 3/02/09 12:50:08

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Protection against
indirect contact (continued)
Maximum theoretical lengths (in m) of conductors protected against indirect contact
by fuse cartridge according to the cross-section of the conductor and the type of fuse
S Rated current of the fuses (in A)
(mm2) 16 20 25 32 40 50 63 80 100 125 160 200 250 315 400 500 630 800 1000 1250
1.5 28 23 18 14 11 9 7 6 5 4
2.5 47 38 30 24 19 15 12 9 8 6 5
4 75 60 48 36 30 24 19 15 12 10 8 6 5 4
6 113 90 72 57 45 36 29 23 18 14 11 9 7 6 5 4
10 188 151 121 94 75 60 48 36 30 24 19 15 12 10 8 6 5 4
16 301 241 193 151 121 96 77 60 48 39 30 24 19 15 12 10 6 6 5 4
25 470 377 302 236 188 151 120 94 75 60 47 38 30 24 19 15 12 9 8 6
aM 35 658 627 422 330 264 211 167 132 105 84 66 53 42 33 26 21 17 13 11 8
50 891 714 572 447 357 286 227 179 144 115 90 72 57 46 36 29 23 18 14 11
70 845 660 527 422 335 264 211 169 132 105 84 67 53 42 33 26 21 17
95 895 716 572 454 358 286 229 179 143 115 91 72 67 45 36 29 23
120 904 723 574 452 362 289 226 181 145 115 90 72 57 45 36 29
150 794 630 496 397 317 248 198 159 126 99 79 63 50 40 32
185 744 586 469 375 293 234 188 149 117 94 74 59 47 38
240 730 584 467 365 292 234 185 146 117 93 73 58 47
300 702 582 439 351 281 223 175 140 111 88 70 66

S Rated current of the fuses (in A)

(mm2) 16 20 25 32 40 50 63 80 100 125 160 200 250 315 400 500 630 800 1000 1250
1.5 53 40 32 22 18 13 11 7 6 4 3
2.5 88 66 53 36 31 21 18 12 9 7 6 4
CHECKING THE MAXIMUM PROTECTED LENGTHS

4 141 106 85 58 33 29 19 15 11 9 8 6 4
6 212 159 127 87 73 60 43 29 22 16 14 10 8 6 4
10 353 265 212 145 122 84 72 48 37 27 23 16 14 10 7 6 4
16 566 424 339 231 196 134 116 77 69 43 36 25 22 15 12 9 7 6 4
25 884 663 530 381 306 209 181 120 92 67 57 40 35 24 18 14 11 8 6 4
gG 35 928 742 606 428 293 263 169 129 94 80 56 48 34 26 20 15 11 9 6
50 667 581 398 343 229 176 128 108 76 66 46 35 27 20 15 12 8
70 856 586 506 337 259 189 159 111 97 67 52 39 30 22 17 11
95 795 887 458 351 256 151 131 92 70 63 29 41 29 23 16
120 868 578 444 323 273 191 166 116 89 67 52 37 29 20
150 615 472 343 290 203 178 123 94 71 54 39 31 21
185 714 547 399 336 235 205 142 110 82 64 46 36 24
240 666 485 409 286 249 173 133 100 77 55 44 29
300 566 477 334 290 202 155 117 90 65 51 34

NB: For cross-sections greater than 300 mm2, the reactance value of the cables must be taken into account.

44

EX29008_p44.indd 44 3/02/09 12:50:21

 SOLUTIONS WHEN THE TRIPPING CONDITIONS ARE NOT MET

In TN and IT systems, when it is not possible to comply

with or verify the protection conditions, several other
4 CREATING ADDITIONAL
solutions may be considered: EQUIPOTENTIAL LINKS
These links must include all the conductive elements
1 USE OF RESIDUAL CURRENT DEVICES that are simultaneously accessible, such as the
exposed conductive parts of devices, metal beams,
The fault current remains high enough to allow the
reinforcements in concrete. The protective conductors
use of low sensitivity residual current devices (300 mA
of all the equipment and those of the power sockets
to 1 A). As in TT systems, it is therefore no longer
must also be connected to these links. The effective-
necessary to verify the fault current value.
ness of this solution must be verified by measuring
the actual resistance between the exposed conductive
2 USE OF “LOW MAGNETIC” parts that are simultaneously accessible.
CIRCUIT BREAKERS
OR CURVE B CIRCUIT BREAKERS
As the magnetic protection level of these devices
is lower, longer length cables are protected.
The possible disadvantage could be false tripping
on current peaks when the circuit supplies specific
receivers (for example: activation of LV/LV
transformers, motor starting, etc.).

SOLUTIONS WHEN THE TRIPPING CONDITIONS ARE NOT MET

3 INCREASING THE CROSS-SECTION
< On-site
Increasing the cross-section of the conductors raises measurement
the fault current to a value that is sufficient to ensure of the end of line
that the overcurrent protection devices trip. short-circuit
value provides
practical
validation
of the choice
of protection

45

EX29008_p45.indd 45 3/02/09 12:50:32

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Estimating It is essential to determine the short-circuit

values at all points in an installation in order
to select the equipment.
short-circuits and This starts with estimating this value at the
origin of the installation, then at any point using

calculation example a number of methods which are selected

according to the size of the installation,
the available data, the type of verification
to be carried out, etc.

SHORT-CIRCUIT VALUE AT THE ORIGIN OF THE INSTALLATION

Several calculation methods can be used to estimate short-circuit currents: a rigorous method called
the “impedance method” and two approximate methods called the “conventional method”
and the “composition method” respectively.
The impedance method consists of adding together the resistances and reactances of the fault loops
from the source up to the point in question and calculating the equivalent impedance. The various short-
circuit and fault currents are then worked out by applying Ohm's Law. This method can be used when
all the characteristics of the constituent elements of the fault loops are known.
The conventional method is based on the hypothesis that during a fault the voltage at the origin of the circuit
is equal to 80% of the nominal voltage of the installation. It is used when the short-circuit at the origin of the
circuit and the upstream characteristics of the installation are not known. It enables the minimum short-
circuits to be determined and the tables of the maximum protected lengths to be established (see p. 32
and 40). It is valid for circuits some distance from the source and is not applicable for installations supplied
by alternators.
The composition method is used when the short-circuit at the origin of the circuit is known, but the
upstream characteristics of the installation are not. It enables the maximum short-circuits at any point
in the installation to be determined.
SHORT-CIRCUIT VALUE AT THE ORIGIN OF THE INSTALLATION

m: no-load factor taken as being 1.05

1 SUPPLY VIA HVA/LV TRANSFORMER Un: nominal phase-to-phase voltage of the installation,
In the case of supply via an HVA/LV transformer, it is in V
advisable to take the impedance of the transformer SkQ: short-circuit power of the HV supply, in kVA
and also that of the HV supply upstream into account. In the absence of precise information from the energy
distribution company, standard IEC 60909 recom-
1.1 Impedance of the HV supply mends calculating the resistances and reactances
The impedance of the HV supply, seen from the LV as follows:
side, can be obtained from the energy distribution
company, measured or calculated using the following RQ = 0.1 × XQ and XQ = 0.995 × ZQ (values in mΩ).
formulae: By default, use SkQ = 500 MVA

(in mΩ)

46

EX29008_p46.indd 46 3/02/09 12:50:44

 1.2 Impedance of the transformer The resistance and reactance values are sometimes
given by the manufacturer. If not, they must be
(in mO) calculated using the formulae below:
S
RS = 0.31 × ZS and XS = 0.95 × ZS (values in mO)
m: no-load factor, taken as being 1.05 The following tables give the maximum three-phase
Un: nominal phase-to-phase voltage of the installation, resistance, reactance and short-circuit values (zero HV
in V impedance) for immersed and dry-type transformers.
STr: rated operating power of the transformer, in kVA These values have been calculated according to the
USC: short-circuit voltage of the transformer, as a % information provided in CENELEC guide R064-003.

Three-phase transformers immersed in a liquid dielectric

Values calculated for a no-load voltage of 420 V (1)
S (kVA) 50 100 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500

In (A) 69 137 220 275 344 433 550 687 866 1100 1375 1718 2200 2749 3437

Usc (%) 4 4 4 4 4 4 4 4 4 6 6 6 6 6 6

Ik3 (kA) 1.81 3.61 5.78 7.22 9.03 11.37 14.44 18.05 22.75 19.26 24.07 30.09 38.52 48.15 60.18

RTR (mO) 43.75 21.9 13.7 10.9 8.75 6.94 5.47 4.38 3.47 4.10 3.28 2.63 2.05 1.64 1.31

XTR (mO) 134.1 67 41.9 33.5 26.8 21.28 16.76 13.41 10.64 12.57 10.05 8.04 6.28 5.03 4.02

SHORT-CIRCUIT VALUE AT THE ORIGIN OF THE INSTALLATION

Three-phase dry-type transformers
Values calculated for a no-load voltage of 420 V (1)
S (kVA) 100 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500

In (A) 137 220 344 344 433 550 687 866 1100 1375 1718 2199 2479 3437

Usc (%) 6 6 6 6 6 6 6 6 6 6 6 6 6 6

Ik3 (kA) 2.41 3.85 4.81 6.02 7.58 9.63 12.04 15.17 19.26 24.07 30.09 38.52 48.15 60.18

RTR (mO) 32.8 20.5 16.4 13.1 10.42 8.2 6.52 5.21 4.10 3.28 2.63 2.05 1.64 1.31

XTR (mO) 100 62.8 50.3 40.2 31.9 25.1 20.11 15.96 12.57 10.05 8.04 6.28 5.03 4.02

(1) According to IEC 60076 (international standard) or HD 398 (harmonised European standard)
The short-circuit values given in manufacturers' catalogues may be slightly lower as they are generally calculated for a voltage of 410 V

47

EX29008_p47.indd 47 3/02/09 12:50:55

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Estimating short-circuits
and calculation example (continued)
Transformers in parallel

To ensure correct operation of transformers in parallel (seethe “Power

analysis and selection of sources" book), the following conditions must be T1 T2 T3
verified: IccT1 IccT2 IccT3
- Same transformation ratio on all connectors
- Same time index
- Same short-circuit voltage (tolerance 10%)
- Rated power ratio between 0.5 and 2
D1 D2 D3
Determination of the breaking capacities of the devices

Breaking capacity of a supply circuit breaker

(e.g. : circuit breaker D1)
This must be at least equal to whichever is higher: the maximum short-circuit D4
(IkT1) generated by transformer T1 (for a short-circuit downstream from
D1) or the sum of all the short-circuits (IkT2 + IkT3) generated by the other
connected transformers (for a short-circuit upstream from circuit
breaker D1).

Breaking capacity of an outgoing line circuit breaker

(e.g. : circuit breaker D4)
This must be at least equal to the sum of all the maximum short-circuits generated
by all the connected transformers (IkT1 + IkT2 + IkT3).
SHORT-CIRCUIT VALUE AT THE ORIGIN OF THE INSTALLATION

2 SUPPLY VIA THE MAINS

The short-circuit current values to be taken into
account depend on the local supply conditions. (transient reactance, in mO) and
The energy distribution company will be able
to provide these values.

3 SUPPLY VIA AN ALTERNATOR (zero phase-sequence reactance, in mO)

The short-circuit values can be calculated as follows m: no-load factor, taken as being 1.05
(CENELEC R064-003): c: voltage factor, taken as being 1.05 for the maximum
values and 0.95 for the minimum values
Un: nominal phase-to-phase voltage, in V
U0: phase-to-neutral voltage, in V
SG: alternator power rating, in kVA
x’d: transient reactance, as a %, taken as being 30%
in the absence of more precise information
x0: zero phase-sequence reactance, as a %, taken as
being 6% in the absence of more precise information.

48

EX29008_p48-63.indd 48 30/01/09 15:05:49

 Maximum three-phase short-circuit values for an alternator according to its power rating
(Un = 400 V and x’d = 30%)
P
100 160 200 250 315 400 500 630 800 1000 1250
(kVA)

Ik3max (kA) 0.53 0.85 1.06 1.33 1.67 2.12 2.65 3.34 4.24 5.30 6.63

Due to their high internal impedance, For alternators, the two-phase short-circuit
alternators generate short-circuit currents value may be lower than that of a single phase
that are much lower than those generated short-circuit. In this case, the two-phase
by transformers of equivalent power. short-circuit value (Ik2) must be taken into
The breaking capacities of the protection account in calculations that require a minimum
devices will be lower, but protection against short-circuit value (line lengths, protection
minimum short-circuits and indirect contact against indirect contact, etc.).
will be more difficult to achieve.
The development of a short-circuit which
appears at the terminals of an alternator
can be broken down into three periods:
- Subtransient period: 10 to 20 ms, during
which the short-circuit level is at its highest
(> 5 In)
- Transient period: up to 200 to 300 ms, during

SHORT-CIRCUIT VALUE AT THE ORIGIN OF THE INSTALLATION

which the short-circuit is in the region of 3
to 5 In
- The short-circuit level then stabilises
at a level of 0.3 to 5 In according to the type
of excitation of the alternator.

When an installation is supplied by several different types of source, for example one or more transformers
as normal source and a generator as a replacement (or backup), the protection devices must be suitable
for the characteristics of the various types of source.
The maximum short-circuits must be calculated by comparing the maximum short-circuit level that may
be generated by all the sources that can operate simultaneously and selecting the maximum value.
This generally involves transformers in parallel. The minimum short-circuits must be calculated
by comparing the minimum short-circuit level generated by each of the sources and selecting
the minimum value.

49

EX29008_p48-63.indd 49 30/01/09 15:05:50

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Estimation of short-circuits
and calculation example (continued)
SHORT-CIRCUIT VALUE AT ANY POINT
1 IMPEDANCE METHOD Linear reactance of the conductors to be used
Using this method, it is possible to determine the value according to the type of cable
of a short-circuit at any point in the installation
by adding together the resistances and reactances and its installation method
of the fault loop from the source up to the point in Linear reactance λ
Cables and installation methods
(mO/m)
question and calculating the equivalent impedance.
The short-circuit values are then calculated Multi-core or single-core cables in
0.08
by applying Ohm's Law (general formula): trefoil arrangement
Single-core cables touching in flat
0.09
layers
Single-core cables more than one
0.13
c: voltage factor taken as being 0.95 for minimum diameter's width apart
short-circuits and 1.05 for maximum short-circuits
m: load factor taken as being 1.05
U0: phase-to-neutral voltage of the installation, in V Resistivity of the conductors to be used according
ZSC: total impedance of the fault loop at the point to the type of short-circuit calculated
in question This is the vectorial sum of the resistances (ρ 0: resistivity of the conductors at 20°C)
and reactances that make up the loop.
The impedances of the cables are estimated using Cu Al
Fault Resistivity
(O mm2/m) (O mm2/m)
the following formulae:
Isc maximum ρ0 0.01851 0.0294
(in mO) Circ. breaker ρ1 = 1.25
0.02314 0.0368
ρ0
Isc minimum
ρ: resistivity of the conductor, inOmm2/m Fuse ρ1 = 1.5 ρ0 0.02777 0.0441
(see table opposite)
Sc: cross-section of the conductor, in mm2 If ρ1 = 1.25 ρ0 0.02314 0.0368
nc: number of conductors in parallel
Thermal
L: length of the conductor, in m ρ1 = 1.25 ρ0 0.02314 0.0368
stresses
SHORT-CIRCUIT VALUE AT ANY POINT

(in mO)

λ: linear reactance of the conductor, in mO/m (see

table opposite)
Sc: cross-section of the conductor, in mm2
nc: number of conductors in parallel
L: length of the conductor, in m

50

EX29008_p48-63.indd 50 30/01/09 15:05:50

 Calculation of the various types of maximum and minimum
short-circuits using the general formula
Three-phase short-circuit current:

Two-phase short-circuit current:

To calculate the minimum two-phase short-circuit, replace:

- ρ0 with ρ1 for protection using circuit breakers or with ρ2 for fuse protection
- cmax with cmin.

Phase-neutral single phase short-circuit current:

To calculate the minimum single phase short-circuit current, replace:

- ρ0 with ρ1 for protection using circuit breakers or with ρ2 for fuse protection
- cmax with cmin.

Fault current:

cmax, cmin: voltage factor taken as being 0.95 (cmin) RPEa, XPEa: resistance and reactance of a protective
for minimum short-circuits and 1.05 (cmax) for maximum conductor from the source up to the origin of the circuit
short-circuits in question. It is the sum of the resistances R and the
SHORT-CIRCUIT VALUE AT ANY POINT

m: load factor taken as being 1.05 reactances X of the upstream cables.

α: 1 in TN system, 0.86 in IT system without neutral ρ0, ρ1, ρ2: resistivity of the conductors (see table
and 0.5 in IT system with neutral on previous page)
U0: phase-to-neutral voltage of the installation, in V λ: linear reactance of the conductors (see table
RQ, XQ: equivalent resistance and reactance of the HV on previous page)
supply L: length of the circuit in question, in m
RS, XS: equivalent resistance and reactance of the source SPh, nPh: cross-section and number of conductors
RPha, XPha: resistance and reactance of the phase in parallel per phase of the circuit in question
conductors from the source up to the origin of the circuit SN, nN: cross-section and number of conductors
in question. It is the sum of the resistances R and the in parallel for the neutral of the circuit in question
reactances X of the upstream cables. SPE, nPE: cross-section and number of conductors
RNa, XNa: resistance and reactance of a neutral conductor in parallel for the PE of the circuit in question
from the source up to the origin of the circuit in question.
It is the sum of the resistances R and the reactances X
of the upstream cables.
51

EX29008_p48-63.indd 51 30/01/09 15:05:50

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Estimating short-circuits
and calculation example (continued)
This method applies to installations whose power
2 COMPOSITION METHOD does not exceed 800 kVA. The maximum short-circuit
This method is a simplified approach. With a current at any point in the installation is determined
knowledge of the three-phase short-circuit current using the following tables, based on the:
at the origin of the installation (see previous section), - Prospective short-circuit current at the supply end
this approach enables the prospective short-circuit of the installation
current Ik3 at the end of a wiring system of given - Length of the line
length and cross-section to be estimated. - Type and cross-section of the conductors

Aluminium conductors - 240/400 V

Ik3 upstream
Short-circuit current at the level in question (Ik3 downstream in kA)
(kA)
100 93.5 91.1 87.9 83.7 78.4 71.9 64.4 56.1 47.5 39.0 31.2 24.2 18.5 13.8 10.2 7.4 5.4 3.8 2.8 2.0 1.4 1.0
90 82.7 82.7 80.1 76.5 72.1 66.6 60.1 52.8 45.1 37.4 30.1 23.6 18.1 13.6 10.1 7.3 5.3 3.8 2.7 2.0 1.4 1.0
80 74.2 74.2 72.0 69.2 65.5 61.0 55.5 49.2 42.5 35.6 28.9 22.9 17.6 13.3 9.9 7.3 5.3 3.8 2.7 2.0 1.4 1.0
70 65.5 65.5 63.8 61.6 58.7 55.0 50.5 45.3 39.5 33.4 27.5 22.0 17.1 13.0 9.7 7.2 5.2 3.8 2.7 1.9 1.4 1.0
60 56.7 56.7 55.4 53.7 51.5 48.6 45.1 40.9 36.1 31.0 25.8 20.9 16.4 12.6 9.5 7.1 5.2 3.8 2.7 1.9 1.4 1.0
50 47.7 47.7 46.8 45.6 43.9 41.8 39.2 36.0 32.2 28.1 23.8 19.5 15.6 12.1 9.2 6.9 5.1 3.7 2.7 1.9 1.4 1.0
40 38.5 38.5 37.9 37.1 36.0 34.6 32.8 30.5 27.7 24.6 21.2 17.8 14.5 11.4 8.8 6.7 5.0 3.6 2.6 1.9 1.4 1.0
35 33.8 33.8 33.4 32.8 31.9 30.8 29.3 27.5 25.2 22.6 19.7 16.7 13.7 11.0 8.5 6.5 4.9 3.6 2.6 1.9 1.4 1.0
30 29.1 29.1 28.8 28.3 27.7 26.9 25.7 24.3 22.5 20.4 18.0 15.5 12.9 10.4 8.2 6.3 4.8 3.5 2.6 1.9 1.4 1.0
25 24.4 24.4 24.2 23.8 23.4 22.8 22.0 20.9 19.6 18.0 16.1 14.0 11.9 9.8 7.8 6.1 4.6 3.4 2.5 1.9 1.3 1.0
20 19.6 19.6 19.5 19.2 19.0 18.6 18.0 17.3 16.4 15.2 13.9 12.3 10.6 8.9 7.2 5.7 4.4 3.3 2.5 1.8 1.3 1.0
15 14.8 14.8 14.7 14.6 14.4 14.2 13.9 13.4 12.9 12.2 11.3 10.2 9.0 7.7 6.4 5.2 4.1 3.2 2.4 1.8 1.3 0.9
10 9.9 9.9 9.9 9.8 9.7 9.6 9.5 9.3 9.0 8.6 8.2 7.6 6.9 6.2 5.3 4.4 3.6 2.9 2.2 1.7 1.2 0.9
7 7.0 7.0 6.9 6.9 6.9 6.8 6.7 6.6 6.5 6.3 6.1 5.7 5.3 4.9 4.3 3.7 3.1 2.5 2.0 1.6 1.2 0.9
5 5.0 5.0 5.0 5.0 4.9 4.9 4.9 4.8 4.7 4.6 4.5 4.3 4.1 3.8 3.5 3.1 2.7 2.2 1.8 1.4 1.1 0.8
4 4.0 4.0 4.0 4.0 4.0 3.9 3.9 3.9 3.8 3.8 3.7 3.6 3.4 3.2 3.0 2.7 2.3 2.0 1.7 1.3 1.0 0.8
3 3.0 3.0 3.0 3.0 3.0 3.0 3.0 2.9 2.9 2.9 2.8 2.7 2.6 2.5 2.4 2.2 2.0 1.7 1.5 1.2 1.0 0.8
2 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 1.9 1.9 1.9 1.8 1.8 1.7 1.6 1.5 1.3 1.2 1.0 0.8 0.7
1 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.9 0.9 0.9 0.8 0.8 0.7 0.7 0.6 0.5
Phase
conductor
Length of the wiring system (in metres)
cross-section
(mm2)
2.5 1.3 1.9 2.7 3.8 5.4 7.6 10.8 15 22
4 1.1 1.5 2.2 3.0 4.3 6.1 8.6 12 17 24 34
6 1.6 1.7 2.5 3.5 4.9 7.0 9.9 14 20 28 40
10 1.5 2.1 2.9 4.1 5.8 8.2 11.6 16 23 33 47 66
16 2.2 3.0 4.3 6.1 8.6 12 17 24 34 49 69 98 138
25 1.7 2.4 3.4 4.8 6.7 9.5 13 19 27 38 54 76 108 152 216
SHORT-CIRCUIT VALUE AT ANY POINT

35 1.7 2.4 3.3 4.7 6.7 9.4 13 19 27 38 53 75 107 151 213 302
50 1.6 2.3 3.2 4.5 6.4 9.0 13 18 26 36 51 72 102 145 205 290 410
70 2.4 3.3 4.7 6.7 9.4 13 19 27 38 53 75 107 151 213 302 427
95 2.3 3.2 4.5 6.4 9.0 13 18 26 36 51 72 102 145 205 290 410
120 2.9 4.0 5.7 8.1 11.4 16 23 32 46 65 91 129 183 259 366
150 3.1 4.4 6.2 8.8 12 18 25 35 50 70 99 141 199 281 398
185 2.6 3.7 5.2 7.3 10.4 15 21 29 42 59 83 117 166 235 332 470
240 1.6 2.3 3.2 4.6 6.5 9.1 13 18 26 37 52 73 103 146 207 293 414
300 1.4 1.9 2.7 3.9 5.5 7.8 11 16 22 31 44 62 88 124 176 249 352 497
2 x 120 1.4 2.0 2.9 4.0 5.7 8.1 11.4 16 23 32 46 65 91 129 183 259 366 517
2 x 150 1.6 2.2 3.1 4.4 6.2 8.8 12 18 25 35 50 70 99 141 199 281 398
2 x 185 1.8 2.6 3.7 5.2 7.3 10.4 15 21 29 42 59 83 117 166 235 332 470
2 x 240 2.3 3.2 4.6 6.5 9.1 12.9 18 26 37 52 73 103 146 207 293 414 583
3 x 120 2.1 3.0 4.3 6.1 8.6 12.1 17 24 34 48 69 97 137 194 274 388 549
3 x 150 2.3 3.3 4.7 6.6 9.3 13.2 19 26 37 53 75 105 149 211 298 422 596
3 x 185 2.8 3.9 5.5 7.8 11.0 15.6 22 31 44 62 88 125 176 249 352 498 705
2 x 300 2.8 3.8 5.4 7.8 11 16 22 32 44 62 88 124 176 248 352 498
3 x 240 3.4 4.8 6.9 9.7 13.7 19 27 39 55 78 110 155 219 310 439 621
4 x 240 4.6 6.4 9.2 13 18 26 36 52 74 104 146 206 292 414 586
4 x 300 5.6 7.6 10.8 14.6 22 32 44 64 88 124 176 248 352 496 704
52

EX29008_p48-63.indd 52 30/01/09 15:05:50

 Example
• Line 1 • Line 2
25 kA 11.9 kA 2.4 kA - Ik3 at origin: 25 kA - Ik3 upstream: 11.9 kA rounded up to 15 kA
70 m 22 m - Copper cable: 120 mm2 - Copper cable: 6 mm2
- Length: 75 m (73 m) - Length: 25 m (22 m)

Line 1 Line 2 ⇒ Ik3 downstream: 11.9 kA ⇒ Ik3 downstream: 2.4 kA

Copper conductors - 240/400 V

Ik3 upstream
Short-circuit current at the level in question (Ik3 downstream in kA)
(kA)
100 93.5 91.1 87.9 83.7 78.4 71.9 64.4 56.1 47.5 39.0 31.2 24.2 18.5 13.8 10.2 7.4 5.4 3.8 2.8 2.0 1.4 1.0
90 82.7 82.7 80.1 76.5 72.1 66.6 60.1 52.8 45.1 37.4 30.1 23.6 18.1 13.6 10.1 7.3 5.3 3.8 2.7 2.0 1.4 1.0
80 74.2 74.2 72.0 69.2 65.5 61.0 55.5 49.2 42.5 35.6 28.9 22.9 17.6 13.3 9.9 7.3 5.3 3.8 2.7 2.0 1.4 1.0
70 65.5 65.5 63.8 61.6 58.7 55.0 50.5 45.3 39.5 33.4 27.5 22.0 17.1 13.0 9.7 7.2 5.2 3.8 2.7 1.9 1.4 1.0
60 56.7 56.7 55.4 53.7 51.5 48.6 45.1 40.9 36.1 31.0 25.8 20.9 16.4 12.6 9.5 7.1 5.2 3.8 2.7 1.9 1.4 1.0
50 47.7 47.7 46.8 45.6 43.9 41.8 39.2 36.0 32.2 28.1 23.8 19.5 15.6 12.1 9.2 6.9 5.1 3.7 2.7 1.9 1.4 1.0
40 38.5 38.5 37.9 37.1 36.0 34.6 32.8 30.5 27.7 24.6 21.2 17.8 14.5 11.4 8.8 6.7 5.0 3.6 2.6 1.9 1.4 1.0
35 33.8 33.8 33.4 32.8 31.9 30.8 29.3 27.5 25.2 22.6 19.7 16.7 13.7 11.0 8.5 6.5 4.9 3.6 2.6 1.9 1.4 1.0
30 29.1 29.1 28.8 28.3 27.7 26.9 25.7 24.3 22.5 20.4 18.0 15.5 12.9 10.4 8.2 6.3 4.8 3.5 2.6 1.9 1.4 1.0
25 24.4 24.4 24.2 23.8 23.4 22.8 22.0 20.9 19.6 18.0 16.1 14.0 11.9 9.8 7.8 6.1 4.6 3.4 2.5 1.9 1.3 1.0
20 19.6 19.6 19.5 19.2 19.0 18.6 18.0 17.3 16.4 15.2 13.9 12.3 10.6 8.9 7.2 5.7 4.4 3.3 2.5 1.8 1.3 1.0
15 14.8 14.8 14.7 14.6 14.4 14.2 13.9 13.4 12.9 12.2 11.3 10.2 9.0 7.7 6.4 5.2 4.1 3.2 2.4 1.8 1.3 0.9
10 9.9 9.9 9.9 9.8 9.7 9.6 9.5 9.3 9.0 8.6 8.2 7.6 6.9 6.2 5.3 4.4 3.6 2.9 2.2 1.7 1.2 0.9
7 7.0 7.0 6.9 6.9 6.9 6.8 6.7 6.6 6.5 6.3 6.1 5.7 5.3 4.9 4.3 3.7 3.1 2.5 2.0 1.6 1.2 0.9
5 5.0 5.0 5.0 5.0 4.9 4.9 4.9 4.8 4.7 4.6 4.5 4.3 4.1 3.8 3.5 3.1 2.7 2.2 1.8 1.4 1.1 0.8
4 4.0 4.0 4.0 4.0 4.0 3.9 3.9 3.9 3.8 3.8 3.7 3.6 3.4 3.2 3.0 2.7 2.3 2.0 1.7 1.3 1.0 0.8
3 3.0 3.0 3.0 3.0 3.0 3.0 3.0 2.9 2.9 2.9 2.8 2.7 2.6 2.5 2.4 2.2 2.0 1.7 1.5 1.2 1.0 0.8
2 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 1.9 1.9 1.9 1.8 1.8 1.7 1.6 1.5 1.3 1.2 1.0 0.8 0.7
1 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.9 0.9 0.9 0.8 0.8 0.7 0.7 0.6 0.5
Phase
conductor
Length of the wiring system (in metres)
cross-section
(mm2)
1.5 1.3 1.8 2.6 3.6 5.1 7.3 10.3 15 21
2.5 1.1 1.5 2.1 3.0 4.3 6.1 8.6 12 17 24 34
4 1.7 1.9 2.6 3.7 5.3 7.4 10.5 15 21 30 42
6 1.4 2.0 2.8 4.0 5.6 7.9 11.2 16 22 32 45 63
10 2.1 3.0 4.3 6.1 8.6 12.1 17 24 34 48 68 97 137
SHORT-CIRCUIT VALUE AT ANY POINT

16 1.7 2.4 3.4 4.8 6.8 9.7 14 19 27 39 55 77 110 155 219

25 1.3 1.9 2.7 3.8 5.4 7.6 10.7 15 21 30 43 61 86 121 171 242 342
35 1.9 2.6 3.7 5.3 7.5 10.6 15 21 30 42 60 85 120 170 240 339 479
50 1.8 2.5 3.6 5.1 7.2 10.2 14 20 29 41 58 81 115 163 230 325 460
70 2.6 3.7 5.3 7.5 10.6 15 21 30 42 60 85 120 170 240 339
95 2.5 3.6 5.1 7.2 10.2 14 20 29 41 58 81 115 163 230 325 460
120 1.6 2.3 3.2 4.5 6.4 9.1 13 18 26 36 51 73 103 145 205 291 411
150 1.2 1.7 2.5 3.5 4.9 7.0 9.9 14 20 28 39 56 79 112 158 223 316 447
185 1.5 2.1 2.9 4.1 5.8 8.2 11.7 16 23 33 47 66 93 132 187 264 373 528
240 1.8 2.6 3.6 5.1 7.3 10.3 15 21 29 41 58 82 116 164 232 329 465 658
300 2.2 3.1 4.4 6.2 8.7 12.3 17 25 35 49 70 99 140 198 279 395 559
2 x 120 2.3 3.2 4.5 6.4 9.1 12.8 18 26 36 51 73 103 145 205 291 411 581
2 x 150 2.5 3.5 4.9 7.0 9.9 14 20 28 39 56 79 112 158 223 316 447 632
2 x 185 2.9 4.1 5.8 8.2 11.7 16.5 23 33 47 66 93 132 187 264 373 528 747
3 x 120 3.4 4.8 6.8 9.6 13.6 19 27 39 54 77 109 154 218 308 436 616
3 x 150 3.7 5.2 7.4 10.5 14.8 21 30 42 59 84 118 168 237 335 474 670
2 x 240 3.6 5.2 7.2 10.2 14.6 21 30 42 58 82 116 164 232 328 464 658
3 x 185 4.4 6.2 8.8 12.4 17.5 25 35 49 70 99 140 198 280 396 560
4 x 185 3.8 8.2 11.6 16.4 23 33 46 66 94 132 186 264 374 528 746
4 x 240 7.2 10.4 14.4 20 29 41 60 84 116 164 232 328 464 656
53

EX29008_p48-63.indd 53 30/01/09 15:05:50

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Estimating short-circuits
and calculation example (continued)
CALCULATION EXAMPLE
This example gives a complete calculation
of the installation using the impedance method. Basic data for the example below
In the context of the protection of people, a complete
fault current calculation is also carried out. This is an installation with
As the fault current in this example is always lower a 230/400 V TN system sup-
D1 Busbar
than the single phase short-circuit, it will be used plied via a 630 kVA HVA/LV
as the reference for the setting of the magnetic transformer (Usc: 4%). The
releases of the circuit breakers. D2
Outgoing cable 2
short-circuit power of the
HV supply is 500 MVA.
D3

SkQ = 500 MVA HV supply

(m × Un)2 (1,05 × 400)2
ZQ = = = 0,353 mΩ
SkQ 500000
XQ = 0.995 × ZQ = 0.351 mO and RQ = 0.1 × XQ = 0.035 mO

RQ = 0.035 mO XQ = 0.351 mO

STr = 630 kVA HVA/LV transformer

USC = 4% Calculation of Ik3
In = 909 A (m × Un)2 UCC (1,05 × 400)2 4
ZS = × = × = 11,2 mΩ
STr 100 630 100
RS = 0.31 × ZS = 3.472 mO and XS = 0.95 × ZS = 10.640 mO

RS = 3.472 mO XS = 10.640 mO ΣR = 3.507 mO ΣX = 10.991 mO

⇒ Ik3 = 1,05 × 1,05

2
× 231
2
= 22,07 kA
3,507 + 10,991
Ik3 = 22.07 kA
Incoming cable
Calculation of Ik3
CALCULATION EXAMPLE

L 5
Rc = ρ0 × 103 × = 0,01851 × 103 × = 0,250 mΩ
Copper/XLPE nph × Sph 2 × 185
SPh = 2 × 185 mm2 L 5
SPEN = 2 × 185 mm2 Xc = λ × = 0,08 × = 0,200 mΩ
nph 2
IZ = 984 A
L=5m RC = 0.250 mO XC = 0.200 mO ΣR = 3.757 mO ΣX = 11.216 mO

⇒ Ik3 = 1,05 × 21,05 × 2312 = 21,52 kA

3,757 + 11,216
54

EX29008_p48-63.indd 54 30/01/09 15:05:50

 Calculation of If
Rc = ρ1 × 103 × L (n 1× S
ph ph
+
1
)
nPEN × SPEN (
= 0,02314 × 103 × 5
1
+
1
)
2 × 185 2 × 185
= 0,625 m

Xc = λ × L ( n1
ph
+
1
nPEN )
= 0,09 × 5
1 1
+
2 2 ( ) = 0,45 mΩ
RC = 0.625 mO XC = 0.45 mO ΣR = 4.382 mO ΣX = 11.666 mO
0,95 × 1,05 × 231
⇒ If = 2 2
= 18,92 kA
4,382 + 11,666

Selection and settings of main circuit breaker D1

Rating (In):
This must be at least equal to IB. We will select a 1600 A rated DPX
from the options offered, to allow for expansion of the installation.
Breaking capacity:
Br. capac. ≥ Ik3 ⇒ Br. capac. ≥ 21.57 kA. The breaking capacity of the DPX 1600
is 50 kA.
Number of poles:
Ik3 = 21.57 kA
3P
Thermal setting (Ir):
IB ≤ Ir ≤ IZ ⇒ 909 ≤ Ir ≤ 984 A.
The setting must therefore be between 909 = 0.57 and 984 = 0.62.
1600 1600
If = 18.23 kA We will use Ir = 0.6 × In i.e. Ir = 960 A.
Magnetic setting (Im):
D1 If
Im ≤ 1.2
If: smallest fault at end of line (on busbar)
1,2: 20% tolerance taken into account on the tripping curve
Im ≤ 18230 ⇒ Im ≤ 15191 A
1.2
The maximum possible setting should be used: Im = 10 × Ir = 9600 A.
As a general rule the impedances of the busbars are ignored.

Busbar Selection and settings of outgoing line circuit breaker D2

Rating (In):
This must be at least equal to IB. We will select a 250 A rated DPX 250 ER.
Ik3 = 21.57 kA Breaking capacity:
Br. capac. ≥ Ik3 ⇒ Br. capac. ≥ 21.52 kA. The breaking capacity of the DPX 250 ER
CALCULATION EXAMPLE

is 50 kA.
Number of poles: 4P
Thermal setting (Ir):
D2 IB ≤ Ir ≤ IZ ⇒ 250 ≤ Ir ≤ 268 A. The maximum setting should be used:
Ir = 1 × In = 250 A.
Magnetic setting (Im):
If
Im ≤
1.2
⇒ Im ≤ 4390 ⇒ Im ≤ 3658 A.
1.2
The following setting should be used: Im = 10 × In = 2500 A.
55

EX29008_p48-63.indd 55 30/01/09 15:05:51

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Estimating short-circuits
and calculation example (continued)
Copper/PR Outgoing cable
SPh = 1 × 70 mm2 Calculation of Ik3 (this value will be used to determine the breaking capacity
SN = 1 × 35 mm2 of circuit breaker D3)
SPE = 1 × 35 mm2 L 50
IB = 250 A Rc = ρ0 × 103 × = 0,01851 × 103 × = 13,221 mΩ
nph × Sph 1 × 70
IZ = 268 A
L 50
L = 50 m Xc = λ × = 0,08 × = 4 mΩ
nph 1
cos ϕ = 0.85
RC = 13.221 mO XC = 4 mO ΣR = 17.603 mO ΣX = 15.666 mO

1,05 × 1,05 × 231

⇒ Ik3 = = 10,81 kA
17,6032 + 15,6662

Calculation of If

Rc = ρ1 × 103 × L (n ph
1
+
1
× Sph nPE × SPE ) (
= 0,02314 × 103 × 50
1
+
70 35
1
) = 49,586 mΩ
Xc = λ × L ( n1
ph
+
1
nPE ) ( )
= 0,08 × 50 1 + 1 = 8 mΩ

RC = 13.221 mO XC = 4 mO ΣR = 17.603 mO ∑ΣX = 15.666 mO

0,95 × 1,05 × 231

⇒ If = = 3,9 kA
53,9682 + 19,6662

Calculation of the voltage drop

ISC3 = 10.81 kA L
u = b ( ρ1 cos ϕ + λ L sin ϕ ) IB
S
b = 1 for three-phase
50
Id = 3.9 kA u = (0.02314 × × 0.85 + 0.08 × 10-3 × 50 × 0.527) × 250 = 4.04 V
70

4.04
Δu = × 100 = 1.75%
231

With the knowledge that the voltage drop upstream is 0.14% (value calculated
CALCULATION EXAMPLE

previously), the total cumulative voltage drop is 1.89%.

D3

56

EX29008_p48-63.indd 56 30/01/09 15:05:51

 Checking the calculations with XL PRO 2 Calculation
Using the Legrand calculation software, we can verify The software automatically gives the setting
the accuracy of the results worked out manually of the protection devices
in the previous example.

Results for the line of circuit breaker D2

For the line of the D1 circuit breaker used

in the example, we find the IZ of the cable used, i.e.
for 2 cables of 185 mm2 per phase, an IZ of 984.98 A
CALCULATION EXAMPLE

57

EX29008_p48-63.indd 57 30/01/09 15:05:51

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

The diversity of conductors is virtually unlimited.

Their choice and their identification results from
multiple technical criteria but also from local
Conductors customs. A normative work of harmonization
has been engaged successfully since years,
especially in Europe.
Technical characteristics and uses of the most
common types of installation conductors are
described in this chapter.

SELECTION AND USE OF CABLES AND CONDUCTORS

The requirements applicable to cables and conductors,
their connections, supports and enclosures, and more Some conductors and cables are considered
generally, their protection from external stresses, to provide class II insulation (this degree of
must be considered when designing and implementing insulation can be achieved by placing insulated
electrical installations. conductors in an insulated sheath or conduit).
Standard IEC 60364-5-51 defines installation They must be used where there is a high risk
configurations for cables and conductors known as of contact with the earth potential (conductive
“installation methods” (see p. 08) which determine the enclosures or those with a large number of
conditions for protection against external influences: conductive elements) or when the insulation
temperature, presence of water, presence of conditions are poor (damp areas).
pollution, risk of impact, vibration, fire, poor insulation It may also be necessary to use them
conditions, etc. upstream of devices providing effective
The maximum permissible temperature of the protection against indirect contact.
insulation of the core is taken into account when sizing
conductors (see p. 07 et seq.). Class II cables
The generic name XLPE/PR is given to conductors • U0 500 V: U-1000 R12N, U-1000 R2V,
whose insulation withstands 90°C (cross-linked U-1000 RVFV(1), H07 RN-F, A07 RN-F,
polyethylene, elastomer) FR-N1 X1 X2, FR-N1 X1 G1, H07 VVH2-F
The generic name PVC is given to conductors whose
insulation withstands 70°C (PVC, rubber) • U0 250 V: H05 RN-F, H05 RR-F, H05 VV-F,
H05 VVH2-F, FR-N05 VV5-F, A05 VVH2-F(1)
SELECTION AND USE OF CABLES AND CONDUCTORS

For industrial distribution applications,

the use of cables with elastomer XLPE/PR
insulation is especially recommended:
- Their insulation voltage is higher
(up to 1000 V)
- Their permissible operating temperature
(90°C) and max. short-circuit temperature
(250°C) are suitable for the requirements
of power distribution boards
U-1000 R2V single-core and
- They have excellent mechanical properties
multi-core cable
- They are highly resistant to atmospheric
and chemical agents (1) Depending on the conditions of use

58

EX29008_p48-63.indd 58 30/01/09 15:05:52

 The most commonly used power conductors and cables

Designation
U-1000 R2V U-1000 RVFV
U-1000 RGPFV H07 RN-F
and U-1000 AR2V and U-1000 ARVFV

Buried connection Immersed installation,

Protected mobile
Use Fixed installation or enhanced mechanical chemical attack, high
or fixed installation
protection mechanical protection

Number of conductors 1 to 4 (5 up to 50 mm2) 1 to 4 (5 up to 50 mm2) 2 to 4 (5 up to 225 mm2) 1 to 4

1.5 to 240 mm2
Conductor cross-section 1.5 to 300 mm2 1.5 to 300 mm2 1.5 to 300 mm2
(150 mm2 for 3 cond.)
Core Copper or aluminium Copper or aluminium Copper Flexible copper
Insulation Cross-linked polyethylene Cross-linked polyethylene Cross-linked polyethylene Cross-linked elastomer
Sheath Black PVC Black PVC Black PVC Cross-linked elastomer
lead sheath
Metal covering - 2 steel sleeves -
+ 2 steel sleeves
Nominal voltage 600/1000 V 600/1000 V 600/1000 V 450/750 V

In poor insulation conditions, and also when there is a frequent risk of contact with earth, U-1 000 RVFV type
cables with a metal covering can be used, connecting both ends of the sleeves to the protective conductor.
In very poor insulation conditions, or if people are in permanent contact with earth (conductive enclosure),
or upstream of devices providing protection against indirect contact, and for all conditions requiring class II
wiring systems, U-1 000 RVFV cables can be used, as long as the metal sleeves are not connected
and are insulated from all contact. SELECTION AND USE OF CABLES AND CONDUCTORS

Low voltage connection cables

Designation
H1 XDV-AS
Twisted supply bundle
H1 XDV-AR sector-shaped core,
with messenger NF C 33 209
non-insulated PE conductor
Use Overhead connection Underground connection NF C 32 210
Number of conductors - -
Conductor cross-section 25 to 150 mm2 16 to 240 mm2
Core Aluminium Aluminium
Insulation Cross-linked polyethylene Cross-linked polyethylene
Sheath - PVC
Metal covering - Steel sleeves
Nominal voltage 600/1000 V 600/1000 V

59

EX29008_p48-63.indd 59 30/01/09 15:05:52

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Conductors (continued)
Conductors and cables for domestic, residential, commercial or similar applications

Designation

H07 V-U and H07 V-R H07 V-K and H07 V-K FR-N05 VV-U/FR-NO5 VV-R
Fixed installation (in conduit, Internal wiring or wiring Fixed installation on walls, empty
Use trunking, wiring of terminal fixed installation in trunking construction compartments
board) or conduit (flush-mounting in conduit)
Number of conductors 1 1 2 to 5
Conductor cross-section Up to 400 mm2 Up to 240 mm2 1.5 to 6 mm2
Rigid copper: solid (V-U) Rigid copper: solid (V-U)
Core Flexible copper
or stranded (V-R) or stranded (V-R)
Insulation PVC (numerous colours) PVC PVC
Sheath - - PVC
Nominal voltage 450/750 V H05: 300/500 V - H07: 450/750 V 300/500 V

Conductors and cables for domestic, residential, commercial or similar applications (continued)

Designation
H03VVH2-F H05 RR-F H05 RN-F
H05 VV-F
and H05 VVH2-F and A05 RR-F and A05 RN-F
Supplying mobile
Supplying mobile devices Supplying small machines,
Use or removable domestic Power supply
(in particular heating) motors, inspection lamps
appliances
SELECTION AND USE OF CABLES AND CONDUCTORS

Number of conductors 2 to 5 2 2 to 5 2 or 3
Conductor cross-section 0.75 to 4 mm2 0.5 to 6 mm2 0.5 to 6 mm2 0.75 and 1 mm2
Flexible copper
Core Flexible copper Flexible copper Flexible copper
(plain or tinned)
Insulation PVC PVC Elastomer Elastomer
Sheath PVC PVC Elastomer Elastomer

Note - - Good mechanical strength Good mechanical strength

Nominal voltage 300/500 V H03: 300 V - H05: 500 V 300/500 V 300/500 V

Characterised by ease of use, these cables There are many other types of standardised
have low or medium mechanical strength. and non-standardised cables for specific
Their insulation voltage is 500 or 750 V, applications: fire, control, command, lifts,
their maximum temperature is 70°C in steady handling, indicators, chemical industry, etc.
state (160°C in short-circuit). Their fire Refer to the manufacturers’ catalogues
behaviour classification is C2. for their characteristics and selection.

60

EX29008_p48-63.indd 60 30/01/09 15:05:53

 Symbolic designation of cables: harmonised description
Metal Shape of Flexibility and
Type of range Voltage U0/U Insulation Sheath Type of core
covering cable shape of the core
Rigid, solid, round,
U
< 100 V 00 class 1

no letter
Harmonised Rigid, stranded,
H PVC V PVC V Round cable R
range round, class 2
100/100 V 01 Copper -
Rigid, stranded,
S
sector-shaped
Rigid, solid,
W
300/300 V 03 Steel tape sector-shaped
Recognised around the D
Vulcanised Vulcanised Divisible flat
national A R conductors R H Tinsel conductor Y
rubber rubber cable
range
300/500 V 05
Flexible, class 5 for
K
National fixed installation
450/750 V 07 Aluminium -A
range Non-
Cross-linked Cross-linked Flexible, class 5 F
other than N X N divisible flat H2
polyethlylene polyethylene
recognised cable
0.6/1 kV 1 Extra flexible
range H
class 6

Example: H07 V-K

H: harmonised range; 07: 450/750 insulation; V: PVC insulation; -K: class 5 flexible copper core

Symbolic designation of cables: harmonised description

Type of Voltage Flexibility Metal Shape
Type of core Insulation Filler Protective sheath
SELECTION AND USE OF CABLES AND CONDUCTORS
range Uo of the core covering of cable

Thick sheath 2
Vulcanised
C
rubber Lead
250 V 250 Filler sheath G P
sheath
no letter

no letter

no letter

Very thick grease 3 Round

Rigid Copper
cable
Cross-linked
R
polyethylene
Cable
subject No filler or filler
Steel
to a UTE U 500 V 500 not forming a O Vulcanised rubber C F
sleeves
stand- sheath
ard
PVC V
Flat
Flexible A Alumin. A Polychloroprene N M
Grouping and cable
protective Zinc or
1000 V 1000 I Z
Mineral sheath forming metal
X filler
insulation
PVC V

Example: U-1000 RO2V

U: Covered by a UTE standard; 1000: insulation voltage 1000 V; R: cross-linked polyethylene insulation; O: no filler;
2: thick sheath; V: PVC protective sheath
61

EX29008_p48-63.indd 61 30/01/09 15:05:53

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Conductors (continued)
Conditions of use of the most
External influences (abbreviated

Presence
Presence
of corrosive
Ambient temperature Presence of water of foreign Mechanical shock
or polluting
(AA) (AD) solid bodies (AG)
substances
or dust (AE)
(AF)

Very high severity (IK 10) (6)

Intermittent or accidental

Medium severity (IK 07)

High severity (IK 08)

Low severity (IK 03)
Submersion (IP x8)
Immersion (IP x7)
Splashes (IP x4)

Moderate dust
+5°C to +40°C

+5°C to +60°C
-60°C to +5°C

-40°C to +5°C

-25°C to +5°C

-5°C to +40°C

Waves (IP x6)

Atmospheric
Heavy dust
Negligible

Negligible
Light dust

Cables
AA1 AA2 AA3 AA4 AA5 AA6 AD1 AD4 AD6 AD7 AD8 AE4 AE5 AE6 AF1 AF2 AF3 AG1 AG2 AG3 AG4
U-1000R2V (1) (2)
U-1000AR2V
U-1000RVFV (1) (2)
U-1000ARVFV
U-1000RGPFV (1) (2) o
H07 RN-F (2)
SELECTION AND USE OF CABLES AND CONDUCTORS

H05 RN-F
Torsades 0,6/1 kV
H1 XDV-AR (1) (2)
H1 XDV-AS
H07 V-U (1)
H07 VR
H07 V-K (1)

FR-N 05 VV-U
FR-N 05 VV-R
H05 VV-F
H03 VVH2-F (1)
H05 VVH2-F
H05 RR-F
A05 RR-F

(1) These cables can be used in other temperature conditions (5) According to protection conduit
if they are not subject to any mechanical stress [6] The level IK10 according to IEC 62262 is only used in France
(2) Cumulative immersion period limited to 2 months a year (NF C 15-100)
(3 ) If metallic coverings earth connected [7] The matter is under consideration in the IEC 60364-5-51 but used
(4) Cables permanently fixed and U0 tension limited to 250 V in France (NF C 15-100)

62

EX29008_p48-63.indd 62 30/01/09 15:05:53

 common cables and conductors
designations according to IEC 60364-5-51)

Presence
Electrical Nature
of flora
Presence resistance of processed Construction
Vibration and/or Solar radiation Building design
of fauna of the human or stored materials
(AH) moulds (AN) (CB)
(AL) body(7) materials (CA)
growth
(BB) (BE)
(AK)
Medium severity (industrial)

Medium (500 to 700 W/m²)

Immersed condition

Flexible or unstable
No significant risks

Propagation of fire
Low (<500 W/m²)

Negligibles risks
Non combustible
Explosion risks
Wet Condition
High (700 m²)

Dry condition
High severity
Low severity

Combustible

Movement
No hazard

No hazard

Fire risks
Hazard

Hazard

AH1 AH2 AH3 AK1 AK2 AL1 AL2 AN1 AN2 AN3 BB1 BB2 BB3 BE1 BE2 BE3 CA1 CA2 CB1 CB2 CB3 CB4

(3)

(3)
SELECTION AND USE OF CABLES AND CONDUCTORS

(3)

(5)

(5) (5) (5)

(4)

(4)

(4)

63

EX29008_p48-63.indd 63 30/01/09 15:05:53

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Conductors (continued)
Maximum permitted temperatures (°C)
High High Ethylene-propylene (EPR)
Silicone rubber
Insulation PVC temperature Rubber temperature and cross-linked
(SIR)
PVC rubber polyethylene (XLPE)

Under constant normal

70 90 60 85 90 180
conditions

160
Under short-circuit
140 when 160 200 220 250 350
conditions
S > 300 mm2

Fire behaviour
of cables and conductors
Classification of fire behavior is based on a number
of tests that are defined by international standards
(IEC 60331 and IEC 60332), European (EN 50200)
or national for some types of cables (for example
NF C 32070 for C1 category).
The following “reaction to fire” categories are
distinguished:
- C3: no special characteristics
- C2: flame retardant. Most cables in installations
SELECTION AND USE OF CABLES AND CONDUCTORS

belong to this category.

- C1: fire retardant. Using this class limits the risk
of spreading in flat layers and cable ducting.
FR N1 X1… series cables, and FR-N05 G2 (U, R or K)
and FR-N07 X3 (U, R or K) series conductors belong
to this category.
The following “fire resistance” categories are
distinguished:
- CR2: no special characteristics
- CR1: fire resistant.
U500 X, XV, 1000 X or XV series conductors with
mineral insulation, “Lyonotox” and “Pyrolyon” type
“fire resistant” conductors, and certain (central) power ^ A neat cable layout is essential
or signalling cables belong to this category.
with regard to the fire risk
Class CR1 is for example required in fire safety
installations in public buildings.

64

EX29008_p64-68.indd 64 30/01/09 15:04:05

 CABLE CORES IDENTIFICATION
Identification colors of cores in cables have been compliance is strongly recommended (see next
subject to developments that results in the page). For information, old national habits
harmonization document HD 308 S2. are reminded in the table below.
These rules do not apply to conductors used in the These cables are still widely present in existing
materials and sets assembled at the factory although installations.

Colors of rigid and flexible cable cores according to HD 324 S2 standard

Number of
2 3 4 5 Color Function
conductors
Green-Yellow PE
Blue Neutral
With PE Brown
Black Phases
Gray
Blue Neutral
Brown
Without PE Black
Phases
Gray
Black

Old fixed cables colors in european countries (CENELEC - feb. 1996)

Switzerland
Denmark

Germany

Kingdom
Republic

Republic
Portugal
Hungary
Belgium

Sweden
Norway
Finland
Austria

Ireland
France

Slovak

United
Czech

Italy

PE
CABLE CORES IDENTIFICATION

N
requirements

requirements

requirements

L1
IEC 445
no

no

no

L2 any
exept
L3 above
Prohibited

G-Y and Blue G-Y with Blue marking Black or brown

65

EX29008_p64-68.indd 65 30/01/09 15:04:05

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Conductors (continued)
WIRING IN ASSEMBLIES
The U columns apply when the conductors or cables
1 CROSS-SECTIONS OF CONDUCTORS are separated, not touching or touching in the same
The table on the next page has been drawn up based circuit (installed on supports, with guide rings, or
on the work practices of a great many professionals simple holding devices).
and tests on wired assemblies. The G columns are to be applied when conductors
As with the sizing of wiring systems, the conductors from different circuits are installed touching one ano-
have been divided into two types: ther and grouped together (for example, installation in
- PVC for conductors with PVC or rubber insulation trunking or in strands.)
(generally used for wiring conductors up to 35 mm2). The current-carrying capacities of flexible bars
- XLPE/PR for polyethylene or elastomer conductors are given on p. 67, while those of rigid bars can be
(in practice these are usually reserved for cross- found in the “Distribution” book. The usual cross-
sections greater than 35 mm2). sections of protective conductors (PE) in assemblies
The installation and ambient temperature conditions are given on p. 31.
have been empirically named:
- IP < 30 for conductors installed with good cooling
conditions (enclosure open or naturally ventilated, low The cross-sections of the conductors to be
to medium wiring density, enclosure internal tempera- used for wiring inside assemblies are not
ture similar to the ambient temperature up to 35°C). subject to a single standard document.
- IP > 30 pour les conductors installed in poor cooling • It is difficult to determine the cross-sections
conditions (sealed enclosure, high wiring density, according to the installation methods in
multi-core cables, enclosure internal temperature that IEC 60364-5-52
may reach 50°C). as this requires, for the application of the
correction factors, information that will only
be known after the installation has been
carried out: parts which run vertically, parts
which run horizontally, groups, number
of layers, separate conductors or cables,
Identification of conductors not to mention knowledge of the ambient
temperature in the enclosure, which is always
Three phases distribution inevitably raises the difficult.
question of phase rotation direction, essentially • Standard EN 60439-1 does not recommend
for circuits including engines. So, the adherence cross-sections but stipulates a “current
to a unique and constant color code throughout an range” for the temperature rise tests. The
installation is primodial. Building site installations, conductors taken into consideration have PVC
by nature likely to dismantling and random insulation and the ambient temperature
WIRING IN ASSEMBLIES

connections, are even more sensitive to this problem is not specified.

whose consequences can be severe including for These conditions do not therefore cover all
security. applications.

66

EX29008_p64-68.indd 66 2/02/09 14:32:30

 Guide values for minimum cross-sections in mm 2
IP < 30 IP > 30 Values acc. to
Type of insulation PVC PR PVC PR EN 60439-1
Installation U G U G U G U G
6 1 1.5 0.7511 1 1.5 1.5 1 1 1
In (A)
or rating 10 1.5 2.5 1 1.5 2.5 2.5 1.5 1.5 1.5
of the protec- 16 2.5 2.5 1.5 2.5 2.5 4 1.5 1.5 2.5
tion device
20 2.5 4 2.5 2.5 4 6 2.5 4 2.5
25 4 6 2.5 4 6 10 4 6 4
32 6 10 4 6 10 16 6 10 6
40 10 16 6 10 16 25 10 10 10
50 10 16 10 10 16 35 10 16 10
63 16 25 10 16 25 50 16 25 16
80 25 35 16 25 35 70 25 35 25
100 25 50 25 35 50 95 35 50 35
125 35 70 25 50 70 120 50 70 50
160 70 120 50 70 95 70 95 70
200 95 70 120 95 120 95
250 120 95 150 120 120
315 185 120 240 185 185
400 240 185 300 240 240
NB: The values in the IP > 30 column correspond to the application of a correction factor of 0.71 (PVC) and 0.82 (PR)
to the current value.
The values in the G columns correspond to the application of a correction factor of 0.7 for groups of several circuits.

< Conductors not < Horizontal circulation “in

touching, held in place free air”, only the vertical
with guide rings: U conductors are grouped
installation in trunking: U installation.
WIRING IN ASSEMBLIES

If, as here, the packing

ratio of the vertical
trunking is high: G
< Several circuits in the installation.
same trunking and all
wiring in vertical and
horizontal trunking:
G installation

67

EX29008_p64-68.indd 67 30/01/09 15:04:06

 DIMENSIONING CONDUCTORS AND DETERMINING PROTECTION DEVICES

Conductors (continued)
Incorrect use can result in temperature rises that are
2 DETERMINING FLEXIBLE BARS incompatible with the insulation, disturbance or even
Flexible bars can be used for making connections damage to connected or surrounding equipment.
on devices or for creating links that can be adapted Flexible bars are shaped manually without the need
to virtually any requirement. Guaranteeing safety for any special tools, although some dexterity is
and high quality finish, they provide an undeniably required to achieve a perfect finish.
attractive touch.
Based on the most commonly used sizes and the
Currents Ie (A) and Ithe (A) of Legrand flexible
electrical capacities of the usual nominal values,
bars are given for the following conditions:
the Legrand range of flexible bars is suitable for most
- Ie (IP < 30): maximum permanent current-
connection or linking requirements. carrying capacity in open or ventilated
As with any conductors, the current-carrying enclosures, the positions of the bars and
capacities of flexible bars may vary according relative distance between them allow correct
to the conditions of use: cooling.
- Ambient temperature (actual in enclosure) The temperature in the enclosure must be
- Period of use (continuous or cyclic load), similar to the ambient temperature.
or installation conditions: - Ithe (IP > 30): maximum permanent
- Bars on their own or grouped together (side current-carrying capacity in sealed
by side in contact or with spacers) enclosures. The bars can be installed close
to one another, but must not be in contact.
- Ventilation: natural (IP < 30), forced (fan)
The temperature in the enclosure can reach
or none (IP > 30)
50°C.
- Vertical or horizontal routing
The considerable variability of all these conditions
leads to very different current-carrying capacities
(in a ratio of 1 to 2, or even more).

Flexible bars have higher current-carrying

capacities than cables or rigid bars with the
same cross-section, due to their lamellar
structure (limitation of eddy currents),
their shape (better heat dissipation)
and their permissible temperature (105°C
high temperature PVC insulation). < Connection of a DPX
on a distribution block
using flexible bars
WIRING IN ASSEMBLIES

Current-carrying capacities of Legrand flexible bars

Cat. No. 374 10 374 16 374 11 374 67 374 17 374 12 374 44 374 57 374 58

Cross-section 13 x 3 20 x 4 24 x 4 20 x 5 24 x 5 32 x 5 40 x 5 50 x 5 50 x 10

Ie (A) IP < 30 200 320 400 400 470 630 700 850 1250

Ithe (A) IP > 30 160 200 250 250 520 400 500 630 800

68

EX29008_p64-68.indd 68 30/01/09 15:04:07

 POWER GUIDE:
A complete set of technical documentation

01 | Sustainable 08 | Protection
development and against external
energy efficiency disturbances

02 | Power balance 09 | Operating

and choice of power functions
supply solutions

03 | Electrical 10 | Enclosures
energy supply and assembly
IE D
certification
T IF

CER
04 | Sizing conductors 11 | Cabling
and selecting components and
protection devices control auxiliaries

05 | Breaking 12 | Busbars
and protection and distribution
devices

06 | Electrical 13 | Transport and

hazards and distribution inside
protecting persons an installation

07 | Protection Annexes
against lightning Glossary
effects Lexicon

EX29008

World Headquarters and

International Department
87045 Limoges Cedex-France
☎ : + 33 (0) 5 55 06 87 87
Fax : + 33 (0) 5 55 06 74 55

EX29008-couverture.indd IV 2/02/09 14:29:46