Volume-09-Design Guidelines For Electrical Wiring Installations

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QUALITY POLICY

“We at RDSO, Lucknow are committed to maintain and update


transparent standards of services to develop safe, modern and cost
effective railway technology complying with statutory and regulatory
requirements, through excellence in research, designs and standards
by setting quality objectives, commitment to satisfy applicable
requirements and continual improvements of the quality management
system to cater to growing needs, demand and expectations of
passenger and freight traffic on the railways through periodic review of
quality management systems to achieve continual improvement and
customer appreciation. It is communicated and applied within the
organization and making it available to all the relevant interested
parties.”

ii
PREFACE
As per instructions of Railway Board, CAMTECH, Gwalior has done detail study on safety in low
voltage electrical installations by referring various Indian Standards on the subject and with the help of
experts in this domain.

On the basis of various Indian standards, CAMTECH, Gwalior has already prepared & published eight
volumes under the series “Safety in Electrical Low Voltage Installations”.

This volume-9 on “Design Guidelines for Electrical Wiring Installations ” under the document series
“Safety in Electrical Low Voltage Installations” has been prepared, which gives complete information
regarding Electrical installation from origin of installation to final circuit.

This volume gives detail information of distribution boards, protective devices i.e. MCB/RCCB,
switchboards, cabling/wiring work etc. This volume also consists of detail information of earthing
system in an electrical installation.

This volume also contains design figures and DO’s and Don’t of various electrical installations, which
will also be useful for electrical engineers and technicians while working on electrical wiring
installations.

Technological up-gradation & learning is a continuous process. Please feel free to write to us for any
addition/ modification in this booklet. We shall highly appreciate your contribution in this direction.

Date: 22.11.2023 (Himanshu Maheshwari)


Place: CAMTECH/Gwalior Jt. Director /Electrical
CONTENTS
CHAPTER 1 DISTRIBUTION SYSTEM .............................................................................................. 1
1.1 Introduction/Power supply System....................................................................................... 1
1.2 System of Distribution IN Electrical LV INstallation ................................................................ 1
1.3 DISTRIBUTION BOARD ........................................................................................................ 2
1.4 Location of Distribution Board .............................................................................................. 3
1.5 Switch/Panel Room, ............................................................................................................ 3
1.6 RCCB .................................................................................................................................. 3
1.6.1 Applicability/use .................................................................................................................. 3
1.6.2 Locations/Sectionalizing ...................................................................................................... 4
1.6.3 False or Unwanted Tripping of RCCB ................................................................................... 4
1.6.4 False Tripping of RCCB due to Electronic Loads ................................................................... 4
1.6.5 Sectionalizing of RCCBs ...................................................................................................... 4
1.7 Size of Cable ....................................................................................................................... 5
1.7.1 Introduction ......................................................................................................................... 5
1.8 Guidelines for Labelling: ...................................................................................................... 7
1.8.1 Schematic Diagram ............................................................................................................. 7
1.8.2 Marking of Distribution Board............................................................................................... 7
CHAPTER 2 WIRING ....................................................................................................................... 9
2.1 Load Calculation of Final Circuit ........................................................................................... 9
2.1.1 Load on switch-board-lighting ............................................................................................. 9
2.1.2 Load on switch-board – power ............................................................................................ 9
2.2 Cross-Sectional Area of Wiring Conductors & Rating of MCB ............................................. 10
2.3 System of Wiring ............................................................................................................... 11
2.4 Class of Wiring Conductor ................................................................................................. 12
2.4.1 Solid Conductor (Class 1).................................................................................................. 12
2.4.2 Stranded Circular Conductors (Class 2) ............................................................................. 12
2.4.3 Flexible Conductors (Classes 5 and 6) ............................................................................... 14
2.4.4 Comparison of class 2 & Class % conductor...................................................................... 14
2.5 Type of Circuit ................................................................................................................... 15
2.5.1 Lighting Load Circuit.......................................................................................................... 15
2.6 Termination of Circuit into Switchboard .............................................................................. 15
2.7 Run of Wiring .................................................................................................................... 16
2.7.1 Passing through Walls or Floors ........................................................................................ 16
iv
2.7.2 Joints in Wiring ................................................................................................................. 16
2.8 Socket Outlets ................................................................................................................... 17
2.9 Conduit ............................................................................................................................. 18
2.9.1 Fill factor or space factor ................................................................................................... 18
2.9.2 Size of Conduit .................................................................................................................. 18
2.9.3 Number of Wire in Conduit................................................................................................. 20
2.9.4 Fish Wire ........................................................................................................................... 21
2.9.5 Marking for Non-essential/Essential/UPS/Switch Boards .................................................... 21
CHAPTER 3 EARTHING ................................................................................................................. 22
3.1 Introduction ....................................................................................................................... 22
3.2 Earthing System in Installation ........................................................................................... 22
3.3 Eathing Electrode............................................................................................................... 23
3.4 Main Earthing Terminal (MET)............................................................................................ 23
3.5 Earthing Conductor ............................................................................................................ 23
3.6 Protective Conductor ......................................................................................................... 24
3.6.1 Type of Protective Conductor ............................................................................................. 24
3.6.2 Size of Protective Conductor .............................................................................................. 24
3.6.3 Example ............................................................................................................................ 25
3.6.4 Connection of Protective Conductor ................................................................................... 25
3.7 Type of System Earthing .................................................................................................... 26
3.7.1 TT System ........................................................................................................................ 26
3.7.2 TN System ........................................................................................................................ 26
3.8 Application for Internal E.I. ................................................................................................. 27
CHAPTER 4 DO’S & DON’Ts FOR WIRING GUIDELINES ............................................................... 28
4.1 Main Distribution Board ..................................................................................................... 28
4.1.1 Main Distribution Board ..................................................................................................... 28
4.1.2 Distribution Board.............................................................................................................. 29
4.1.3 Final Distribution Board ...................................................................................................... 29
4.1.4 Final Circuits ..................................................................................................................... 30
4.1.5 Conduits ........................................................................................................................... 31
Annexure 1 Different Correction Factor to be applied to the Current-Carrying Capacities for Cables .. 32
Annexure 2 ...................................................................................................................................... 35
Annexure 3 Dimension of Non-Metallic Conduits (PVC) & Single Core Non-Sheathed Cables with
Rigid Conductor Class 1 or Class 2 ................................................................................... 37
Annexure-4 VALUE OF K1 & K2 ..................................................................................................... 38
Annexure 5 DETAIL WIRING DIAGRAMS FROM MDB TO FINAL CIRCUIT ........................................ 41
LIST OF FIGURES
Figure1: Sample Diagram of Electrical Installations ....................................................................... 1
Figure 2: Sectionalizing of RCCB ................................................................................................... 5
Figure 3: Labelling of Circuits ........................................................................................................ 8
Figure 4: Class 1 Conductor ........................................................................................................ 12
Figure 5: Stranded Circular Non-Compacted Conductors (Class 2) ............................................... 12
Figure 6: Flexible Conductors (Classes 5 and 6) .......................................................................... 14
Figure 7: Bends in Conduit .......................................................................................................... 19
Figure 8: Filling factor in conduit .................................................................................................. 20
Figure 9: Schematic Diagram for TT System in LV Installation ...................................................... 22
Figure 10: Schematic Diagram for TN System in LV Installation ...................................................... 23

LIST OF TABLE
Table 1: Estimated standing leakage current for electrical & electronics appliances: ...................... 4
Table 2: Determination of Load of Lighting Points ......................................................................... 9
Table 3: Determination of Load of Power Points............................................................................ 9
Table 4: Minimum Nominal Cross-Sectional Area of Conductors and MCB for Standard Circuits in
non-residential buildings ............................................................................................... 10
Table 5: Recommended Minimum Nominal Cross-sectional Areas of Conductor for Residential
Building ........................................................................................................................ 11
Table 6: Stranded Conductors for Single Core and Multicore Cables (Class 2) ............................. 13
Table 7: Maximum Operating Temperature for Types of Insulation of Cables................................ 18
Table 8: Maximum Number of PVC Insulated 650/1100 V grade Aluminum / Copper Conductor
conforming to IS 694: 1990 .......................................................................................... 20
Table 9: Minimum Cross-Sectional Area of Protective Conductors (Table 14 of IS 732:2019) ...... 24
Table 10: Size of GI Protective Conductor for 16Sqmm & 10Sq.mm Aluminum & Copper Cable .... 25
Table 11: Maximum Earth fault/ Short circuit Loop Impedance Values for Tripping of MCB’s under
Earth Fault/ Short Circuit ............................................................................................... 26
Table 12: Correction Factor for Ambient Air Temperatures Other Than 30 °C to be applied to the
Current-Carrying Capacities for Cables in the Air ........................................................... 32
Table 13: 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 ................................. 33
Table 14: Reduction Factors for One Circuit or One Multi-core Cable or for a Group of more than One
Circuit, or more than one multi-core cable ..................................................................... 33

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Table 15: Current-Carrying Capacity (in Amperes) of PVC and XLPE cable .................................... 35
Table 16: Reduction factor in D1/D2 installation ........................................................................... 36
Table 17: Dimension of Non-Metallic Conduits (PVC) ................................................................... 37
Table 18: Dimensions of Single Core Non-Sheathed Cables with Rigid Conductor Class 1 or Class 2
.................................................................................................................................... 37
Table 19: Values of k1 for Conductors ......................................................................................... 38
Table 20: Values of k2 for Insulated Protective Conductors not Incorporated in Cables and not
Bunched with other cables ............................................................................................ 38
Table 21: Values of k2 for Bare Protective Conductors in Contact with Cable Covering but not
Bunched with other Cables ........................................................................................... 39
Table 22: Values of k2 for Insulated Protective Conductors as a core Incorporated in a Cable or
Bunched with other cables or Insulated Conductors ....................................................... 39
Table 23: Values of k2 Protective Conductors as a Metallic Layer if a Cable, for example, Armour,
Metallic sheath, Concentric conductor, etc. ................................................................... 39
Table 24: Values of k2 for Bare Conductors where there is no risk of damage to any neighbouring
material by the temperature indicated ............................................................................ 40
ISSUE OF CORRECTION SLIP

The correction slips to be issued in future for this handbook will be numbered as follows:

CAMTECH/E/2023-24/Vol.9:Design Guideline for Electrical Wiring/1.0/ # XX date---

Where “XX” is the serial number of the concerned correction slip (starting from 01
onwards).

Sr. No. Date of Issue Page no. & Item no. modified Remarks

viii
DISCLAIMER

It is clarified that the information given in this booklet does not supersede
any existing provisions of Indian Standards (IS) on the subject, related
matters, and other existing provisions laid down by the Railway Board,
RDSO. This is not a statuary document and instructions given are for the
purpose of guidance only. If at any point contradiction is observed, then
Indian Standards, regulations issued by Government bodies, Railway
Board/RDSO guidelines shall be referred.

OBJECTIVE OF PUBLICATION

To prepare guidelines which can educate the Indian Railway (IR) engineers
and technicians dealing with low voltage electrical installations and other IR
officials about various provisions given in IS standards pertaining to IS 3043-
2018, IS 732:2019.
SAFETY IN ELECTRICAL LOW VOLTAGE INSTALLATIONS

CHAPTER 1 DISTRIBUTION SYSTEM

1.1 INTRODUCTION/POWER SUPPLY SYSTEM


An electrical installation is the complete system of caballing, protective Devices and
apparatus, which is used to feed electrical energy from the position at which it is made
available in the building, concerned to the point or points at which it is to be used.
Generally Electrical system mainly consist of two part
(i) Source
Mainly consist Transformer, LT Panels, Cabling which is feeding supply to Installation
i.e. Building, Quarter etc.

(ii) Electrical Installation


Installation Mainly Consist of Distribution board (MDB/DB/FDB) with protective Devices,
cables/conductor, Final Circuit, switch, socket outlets, other electrical equipment&
earthing etc.

Figure1: Sample Diagram of Electrical Installations

1.2 SYSTEM OF DISTRIBUTION IN ELECTRICAL LV INSTALLATION


Distribution board is an important component of electrical installation, which streamlines
electrical power from its source to utility point with an arrangement for wiring protections at
different levels. Electrical design shall comprise distribution boxes of appropriate type at
appropriate locations.

i. There may be three types of LV installations:

MDB--------DB-------------FDB MDB-------------FDB FDB only


ii. MDB (Main Distribution Board) is where incoming supply is coming in the installation.
iii. DB (Distribution Board) is where incoming supply is coming from MDB and further
circuits are going to FDBs.

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iv. FDB (Final Distribution Board) is from where Final Circuits are going to loads/ switch
boards.
v. The circuit which is connected to single-way of switch board/sub-switch board or
fuse/MCB distribution board for supplying current to one or more load point known as
final circuit General Point.

1.3 DISTRIBUTION BOARD


(Ref: Para 3.2of CPWD General Specification Part-I & Para 6.6.3 of Section 9 Part-1 of
NEC:2023)
(i) Each MDB,DB and FDB shall be controlled by an incoming circuit breaker. Each
outgoing circuit shall be controlled by a circuit breaker.
(ii) For non-residential as far as possible DBs shall be separate for light and power.
(iii) Only MCCB/MCB/ type distribution boards shall be used. HRC/Re-wirable type fuses
shall not be used.
(iv) Each MDB/DB/FDB will have reasonable spare outgoing ways for future expansion.
(v) Balancing of 3-phase circuit shall be done.
(vi) Each MDB/DB/FDB will have reasonable spare outgoing ways for future expansion
(vii) Generally, no distribution board will have more than one source of incoming supply.
More than one incoming supply will be allowed only at main board with proper safety
and interlocking so that only one source can be switched on at a time.
(viii) Distribution boxes are available comprising protection provided in the form of fuses,
miniature circuit breakers (MCB) and moulded case circuit breaker (MCCB).
(ix) Depending on source of electrical supply (single phase or three phase), quantum of
electrical load area and plan of building/premises, distribution boxes of single pole
neutral (SPN)/three pole neutral (TPN) with required number of ways (two, four, eight,
twelve, twenty-four etc.) shall be installed. Options of three phase incoming and single
phase outgoing or three-phase incoming and three-phase/single phase outgoing are
available.
(x) Three phase DBs shall not be used for FDB as far as possible.
(xi) Protection provided at incoming of FDB/DB are single phase (SPN) as well as three-
phase(TPN) MCB depending on the scope and stages of distribution design.
(xii) In case of higher harmonics, the neutral protection will be necessary and hence Double
pole and four Pole MCB shall be used. Feeding of single phase FDB from another single
phase FDB shall be avoided.
(xiii) The bus-bar, neutral link and earth link shall be to carry current under normal and fault
condition .The links shall have sufficient number and size of terminals to accommodate
number of Conductors with different cross sections.
(xiv) Space within the DB shall be sufficient to accommodate the number and size of cables
with required loops without over-crowding.

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1.4 LOCATION OF DISTRIBUTION BOARD


(Ref:- Para 6.6.4 of Section 9 &Para 4.12 of Section 22 of NEC:023)
All distribution board/electrical panel shall comply with following:
(i) It shall be installed in common areas where there is no hindrance to reach and operate
especially during emergency conditions;
(ii) Suggested height shall be above ground such that it is beyond the reach of children. But
the replacement/reset of protective devices shall be in accessible position without aid of
any tackle, for example, at an average height between 1.8 m and 2.1 m;
(iii) The distribution box shall not be located at structural expansion joints of the building.
(iv) In case of dusty environment, the panel shall be adequately protected from dust by
fabricating and constructing electrical panels with appropriate ingress protection class. .
If required, electrical panel room may be kept under positive pressure of clean air or
through any other effective means.
(v) There shall be a load centre to limit length of circuit mains and voltage drop;

1.5 SWITCH/PANEL ROOM,


(Ref:- Para 4.12 of Section 22 & Para 6.6.4 of Section 9 of NEC:023)

(i) A clear space of at least 1m in width shall be provided in front of distribution


board/electrical panel. Switchgears and control panels shall be provided with insulating
floors or mats conforming to IS 15652;
(ii) In case of attachments or bare connections at the back of the switchboard, the space
behind the distribution board/electrical panel shall either be less than 20 cm or more
than 75 cm in width measured from farthest protruding part of any attachment or
conductor;
(iii) If the space behind the distribution board/electrical panel exceeds 75cm, passageway
from either end of the switch board clear to a height of 1.8 m shall be provided;
(iv) There shall be adequate illumination within all the panel rooms to maintain clear visibility.
As per National Lighting Code, it shall between 200 to 300 lux.
(v) Under corrosive, humid and hot conditions, additional precautionary measure shall be
taken to suitably place the panels such as in air-conditioned rooms. NOTE — For more
details. IS/IEC 61439 series shall be referred.
(vi) There shall be a load centre to limit length of circuit mains and voltage drop;
(vii) Switchgears on control panels shall be marked with identification and its intended
functions on front and rear side of panel board. Danger notice as per IS 2551 shall be
displayed conspicuously;

1.6 RCCB
1.6.1 Applicability/use
(Ref:- Para 6.7.5.3 of Section 9 of Part-I NEC:023)
Provision of RCCBs (Current operated RCD) with sensitivity of 30mA shall be made for all
household and similar installations for load of 1kW and above, with voltage levels up to 440 V
and 125 A.

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1.6.2 Locations/Sectionalizing
(Ref:- Para 6.7.5.4 of Section 9 of Part-I NEC:023)

Provision of RCCBs shall be made at suitable locations within wiring installations such that in
case of fault, supply of only that particular section of wiring installation is affected and
investigation to clear the fault is restricted to limited section making procedure faster and
easier.

1.6.3 False or Unwanted Tripping of RCCB


RCCBs may be prone to unwanted tripping due to a number of factors, the most common are
as follows:
1.Impact of standing leakage currents on the installation,
2.Impact of harmonics and high frequency leakage currents,
3. Impact of transient residual currents on an installation (switching),
4. Surge currents caused by lightning strikes.

1.6.4 False Tripping of RCCB due to Electronic Loads


Accumulated leakage currents in protective conductor may cause RCD to operate under non
fault condition (for example, current developed by SMPS of multiple computers, when too
many computers are connected on a circuit etc.)

Table 1:Estimated standing leakage current for electrical & electronics appliances:

S.N. Device Leakage Current (In mA)


1 Computer 1 to 2
2 Printer 0.5 to 1
3 Small Portable appliances 0.5 to 0.75
4 Tele copier/Fax 0.5 to 1
5 Photocopier 0.5 to 1.5

The estimated continuous leakage current of a computer is approximately 2 mA. This leakage
current is very weak and therefore not dangerous. The sum of all the continuous leakage
currents can cause nuisance tripping (as it is not related to a hazardous situation).

To avoid this risk, a continuous leakage current of less than 30% of the sensitivity of the RCCB
is recommended, i.e. 10 mA for a 30 mA RCCB.This gives an order of magnitude of a
maximum of 5/6 computers or other devices downstream of a 30 mA residual current device
to restrict maximum leakage current to 30% of the sensitivity of the RCCB.

1.6.5 Sectionalizing of RCCBs


If outgoing circuits are more, then proper sectionalizing of circuits may be done and 30 mA
RCCB may be provided for each section to avoid nuisance tripping due to inherent leakage
current in electrical equipment.

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Figure 2: Sectionalizing of RCCB

Proper sectionalizing is necessary to avoid false tripping. Where RCCBs are installed in series,
discrimination shall be such that nearest RCCs shall trip first. To achieve such condition, S
type RCCBs with time delay setting may be used instead increasing the rating of RCCB.

1.7 SIZE OF CABLE


(Ref: Para 4.1.3.6 & 5.2.7 of IS 732:2019)

1.7.1 Introduction
During the selection of size of cable/wire from MDB to DB or DB to FDB or FDB to
Load/Circuit, following conditions should be satisfied for protection against overload
𝑰𝑩 ≤ 𝑰𝒏 ≤ 𝑰𝒛

𝑰𝟐 ≤ 𝟏. 𝟒𝟓 × 𝑰𝒛

Where,
In = The rated current of the protective device which are protecting the cable/wire. For
adjustable protective devices, the rated current Inis the current setting selected.
Iz = The continuous current-carrying capacity of the cable after applying all reducing
factor i.e. ambient temperature, Grouping, Installation method.
I2 = The current ensuring effective operation in the conventional time of the protective
device

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For calculating Iz current carrying capacity of conductor/wire to be checked from Annexure-1


and after that all reducing factor i.e. ambient temperature, Grouping, to be applied & final
current to be derived.

Note:-Where sustained over currents less than 𝑰𝟐 occur. In such cases, consideration
should be given to selecting a cable with a larger cross-sectional area.

Example
(1) Selection of size of cable & rating of MCB for Final Circuit

Total connected load is 8A for a circuit. Size of wire & Rating of MCB to be define with
following condition:-
a. The outgoing 2 core PVC insulated wire is to be to be laid in conduit in masonry of
building.
b. 2 No. equally loaded additional circuits with this circuit are also laid in same
conduit..
c. Ambient temperature 35°C is considered
Case (A):- This MCB is connected to fixed load like lighting load.
Case (B) :- This MCB is connected to variable overload may be exist like power point

S.N. Step Case-A Case-B Remarks


1 Connected Load 8 Amp.
2 Rating of MCB (In ) 10 Amp. 𝑰𝑩 ≤ 𝑰𝒏
3 Minimum Current carrying 10 Amp. 10x1.45= (In ≤ Iz ) for fixed load (for Case
capacity of wire (In ≤ Iz ) 14.5 Amp. A).Considering requirement of
overload protection factor for
variable load (Multiply overload
factor of MCB (1.45) to rated
current (for Case B)
4 Apply ambient temperature
reduction factor(by current
Ambient temperature 35°C to be
carrying capacity divided
10/0.94 14.5/0.94 considered., Reduction factor
by reduction factor) from
0.94 from table 10 of Annexure-1
table 33 to 34 of IS
732:2019,
5 Apply reduction factor (by
current carrying capacity 2 No. additional circuits with this
divided by reduction factor) circuit are also laid in same
10/ 14.5/
depending on the number conduit. As per table-12 of
(0.94 x 0.70) (0.94x0.70)
of circuits (grouping) from Annexure-1, reduction factor 0.70
table-36 to 40 of IS will be applicable
732:2019.
6 Deriving the final current 22.04 Amp. 15.20 Amp. (Calculating from S.N.5)
7 Checking of size of wire for
2 core 1.5 Checked from table-13 of
particular size/ core/ 2 core 2.5 Annexure-2 as current carrying
Sq.mm
insulation/ installation from Sq.mm PVC
PVC capacity is 23 Amp:-2 core 2.5
Annex-T of IS 732:2019, insulated
insulated Sq.mm 17 Amp.:-2 core 1.5
which has minimum copper wire
copper wire Sq.mm
Current carrying capacity.

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1.8 Guidelines for Labelling:


1.8.1 Schematic Diagram

First a comprehensive schematic diagram for each building is to be prepared, starting from
MDB, DB & FDB etc. and the manner in which they are connected. This will include essential,
non-essential and UPS systems. Sizes of interconnecting main/sub-main Conductors shall be
indicated.
1.8.2 Marking of Distribution Board
Each Distribution board shall be marked indicating rating of each incoming/outgoing switch
and the details of load/area it feeds. Detail/size of incoming and outgoing Conductor also shall
be marked indicating from where the incoming Conductor has originated. Power/light DBs shall
be marked ‘P’ and ‘L’ respectively.

Following procedure to be adopted for Labelling


A. Count total FDBs, DBs, MDBs in the installation and number them in sequence such as
MDB1, MDB2, DB1, DB2, DB3, FDB1, FDB2, FDB3 and so on.
B. At any Distribution board (MDB, DB or FDB) the name of incomer protective device/
circuit will be based on predecessor distribution board and outgoing protective device/
circuit will be based on successor distribution board respectively.

Format of Labelling:

C. Name of board from where D. Name of Circuit (X or E. Space F. I/C or O/G


supply/circuit is coming/going C) with number

Where:
G. C1, 2, 3, … H. Final circuits originating from Final Distribution Boards (FDBs)
I. X1, 2, 3, … J. Distribution circuits originating from Main Distribution Boards (MDBs),
Distribution Boards (DBs)
K. I/C L. Incoming circuit to MDB, DB, FDB with a space prior to it
M. O/G N. Outgoing circuit from MDB, DB with a space prior to it
Example:
i At MDB, for outgoing circuit X1 which is connected to DB1 will be named as DB1X1 O/G
ii At DB1 for incoming circuit from X1 circuit of MDB will be named as MDBX1 I/C
iii At DB1 for outgoing circuit X1 which is connected to FDB1 will be named as FDB1X1
O/G
iv At FDB1 for incoming circuit from X1 circuit of DB1 will be named as DB1X1 I/C
v At FDB1 for outgoing circuit C1which is connected to switch board1 will be named as
C1 (Location name)
vi At switch board1 for incoming circuit from C1 circuit of FDB1 will be named as FDB1C1

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Figure 3: Labelling of Circuits

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CHAPTER 2 WIRING

2.1 LOAD CALCULATION OF FINAL CIRCUIT


2.1.1 Load on switch-board-lighting
Considering that not more than one circuit shall feed supply to switchboards, the total load of
number of light, fan, 6 A plug outlets shall not exceed 30percent of the maximum current
carrying capacity of the circuit main. Table 2 may be referred for assessing load on a lighting
switch-board.
Table 2: Determination of Load of Lighting Points
(Ref: Table 12 of section-9 of NEC-2023)

S.N. Connected Device on the Outlet of Point Wiring Load Consideration

1 Light point* 50 W
2 Fan point 75 W
3 Power outlet 6A 100 W
NOTES
1* Light point may be utilized for a conventional incandescent lamp/tube light with ballast or
single/group of LED lighting fixtures.
2 Fan shall include all types/sweeps/exhaust.
3 If actual rating of appliance is known, it may be taken into consideration subject to
envisaged changes.

2.1.2 Load on switch-board – power


Table 3 gives general guidelines for power load calculation. It may be considered as envisaged
minimum load of appliance. However, where an appliance of higher power rating is to be
connected, actual rating shall be considered.

Table 3: Determination of Load of Power Points


(Ref: Table 13 of section-9 of NEC-2023)
S.N. Commonly Connected Devices on the Outlet of Power Load Consideration in
Point Watt
1 Bathroom
a) Storage type water heater 2000 2000
b) Instant hot water geyser 3000 3000
2 Dry balcony
a) Washing Machine 2000
b) Dish washer 1500
3 Kitchen
a) Electric Hot Plate 2000
b) Induction hot plate 2000
c) Electric oven 2000
d) Microwave 2000
e) Mixer/grinder 500
f) Fridge 500

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g) Toaster/kettle 800
h) Air fryer 1500
i) Kitchen exhaust hood 350
4 Other
a) A.C 1TR/1.5 TR/2 TR 1250/1500/2000
b) Room heater 1000
c) Computer 150
d) TV 100
e) Iron 800
f) EV charging 1000-3000
NOTES
1) Actual requirement may be checked with OEM.

If loads values are not specified than following ratings may be assumed.

Items Loads in Watts


16A socket outlet 1000 W

2.2 CROSS-SECTIONAL AREA OF WIRING CONDUCTORS & RATING OF


MCB
The minimum cross section area of Line, Neutral & Earth Conductor & Rating & Type of MCB
for Standard Circuits in non-residential buildings are as below.
Table 4: Minimum Nominal Cross-Sectional Area of Conductors and MCB for Standard
Circuits in non-residential buildings
(Ref: - Table-6 of Section-9 Part-1 of NEC: 2023).
S.N. Type of Connected Load/No. of Minimum Size of Maximum
Circuit board/socket Line, Neutral Rating of
&Protective Earth MCB&
Copper Conductor Type#
Maximum 2 boards may be
looped, subject to load < 1 kW
1 Lighting circuits 1.5 Sq.mm 10A& B Type
or Maximum 24 points on two
boards
Maximum 4 Nos. sockets,
1.5 Sq.mm 10A& B Type
subject to total load < 1 kW
2 5/6A Socket
Maximum 8 Nos. sockets,
2.5 Sq.mm 16A& B Type
subject to total load < 2 kW
Maximum 2 Nos. sockets,
3 16A Socket 2.5 Sq.mm 16A& B Type
subject to total load < 2 kW
1 No., subject to total load < 2
4 Appliance < 2kW 2.5 Sq.mm 16A& B Type
kW
1 No., subject to total load < 3
5 Appliance < 3kW 4 Sq.mm 20A& B Type
kW
6 1 No, subject to total load < 6
Appliance < 6kW 6 Sq.mm 25A& B Type
kW

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Note : B type of MCB to be used by default, unless until specified for C type of MCB.

# This rating is considering overload requirement of the circuits having 6/16 A socket
provided in them.

Table 5: Recommended Minimum Nominal Cross-sectional Areas of Conductor for


Residential Building
(Ref:- Table-1 of Section 1,Part-3 of NEC:2023).

Use Minimum Size of Line,


Neutral & Protective Earth
Copper Conductor
Point wiring for light/fan/bell/independent plug 6A 1.5 mm2
Branch circuit (DB to switch board) limited to total 10 1.5 mm2
points/800W
Branch circuit (DB to 6/16A power outlets 2 Nos.) for general 2.5 mm2
use or 1 No. independent point for Water heater/Microwave
/OTG/Induction, total max. load 3 kW/circuit
Branch circuit (DB to 16/25A power point 1 No.) e.g. A.C. 4.0 mm2
2TR/3TR total max. load 5kW/circuit.
Mains/sub-mains for total connected load up to 5 kW 4 mm2
Mains/sub-mains for total connected load > 5 kW and < 7 kW 6 mm2

Mains/sub-mains for total connected load > 7 kW and < 10 10 mm2/4 mm2 or 6
kW mm2 (4 + E)*
* For 3-ph supply and load un-balance within 10 percent use 4 mm2, if load un-balance
likely to exceed, use 6 mm2 (4+E)

2.3 SYSTEM OF WIRING


(Ref: Para 3.2& 3.5 of CPWD General Specification Part-I)
(i) ‘Power’ wiring shall be kept separate and distinct from light wiring, from the level of
circuits, i.e., beyond the branch distribution boards. Conduits for light/power wiring shall
be separate.
(ii) Essential/non-essential/UPS distribution each will have a completely independent and
separate distribution system starting from the main, switchboard upto
finalwiringforeachsystem.Asforexample,conduitcarryingnon-essentialwiringshallnot have
essential or UPS wiring. Wiring for essential and UPS supply will have their own conduit
system. No mixing of wiring is allowed.
(iii) Colour Coding
Following colour coding shall be followed in wiring(Ref:- Annex-E-1 of Section 9 of
NEC:023):
Phase : Red/Yellow/Blue.(Three phase wiring)
Live : Red (Single phase wiring)

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Neutral : Black
Earth : Green & Yellow

2.4 CLASS OF WIRING CONDUCTOR


(Ref:- Para 5 of of IS 8130 :2013)
The conductors have been divided into four classes as follows:

Cables Classes Applications


Cables for fixed Classes 1 and 2 Conduit wiring, concealed
installations wiring, etc.
The Flexibles Classes 5 and 6 Panel wiring
Copper welding cables Class 6 Welding cables

2.4.1 Solid Conductor (Class 1)


Conductor consists of single wire of plain or tinned annealed
copper or plain aluminum.
Solid copper conductor shall be of circular cross section.

Figure 4: Class 1 Conductor

2.4.2 Stranded Circular Conductors (Class 2)


(A) Non-Compacted Conductors

Conductor consists of plain or tinned annealed copper or plain


aluminum. The wires in the conductor have the same nominal
diameter before stranding. The number of wires in the
conductor shall be not less than the appropriate minimum
number given in table 2 of IS 8130: 2013.

Figure 5: Stranded Circular Non-Compacted Conductors (Class 2)

(B) Compacted Circular Conductors and Shaped Conductors (Class 2)


Conductor consists of plain or tinned annealed copper or
plain aluminum. The ratio of the diameters of two wires
before stranding in the same conductor shall not exceed 2.
The number of wires in the conductor shall be not less than
appropriate minimum number given in table 2 of IS 8130:
2013.

Figure 5: Compacted Circular Conductors and Shaped Conductors (Class 2)

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Table 6: Stranded Conductors for Single Core and Multicore Cables (Class 2)
(Clause 6.2.3, 6.3.3 and 7.3.1)

S.No. Nominal Minimum Number of Wires in the Maximum Resistance of Conductor at


cross- Conductor 20°C
sectional area Circular conductor Circular Compacted Copper conductor Aluminium
(Non Compacted) or Shaped conductor
conductor
2
(1) mm Cu Al Cu Al Plain wires Tinned /km
(2) (3) (4) (5) (6) /km wires /km (9)
(7) (8)
i. 1 3 -- -- -- 18.1 18.2 --
ii. 1.5 3 3 -- -- 12.1 12.2 18.1
iii. 2.5 3 3 -- -- 7.41 7.56 12.1
iv. 4 7 3 -- -- 4.61 4.70 7.41
v. 6 7 3 -- -- 3.08 3.11 4.61
vi. 10 7 7 6 -- 1.83 1.84 3.08
vii. 16 7 7 6 6 1.15 1.16 1.91
viii. 25 7 7 6 6 0.727 0.734 1.20
ix. 35 7 7 6 6 0.524 0.529 0.868
x. 50 19 19 6 6 0.387 0.391 0.641
xi. 70 19 19 12 12 0.268 0.270 0.443
xii. 95 19 19 15 15 0.193 0.195 0.320
xiii. 120 37 37 18 15 0.153 0.154 0.253
xiv. 150 37 37 18 15 0.124 0.126 0.206
xv. 185 37 37 30 30 0.0991 0.100 0.164
xvi. 240 61 37 34 30 0.075 4 0.076 2 0.125
xvii. 300 61 61 34 30 0.060 1 0.060 7 0.100
xviii. 400 61 61 53 53 0.047 0 0.047 5 0.077 8
xix. 500 61 61 53 53 0.036 6 0.036 9 0.060 5
xx. 630 91 91 53 53 0.028 3 0.028 6 0.046 9
1)
xxi. 800 91 91 53 53 0.022 1 0.022 4 0.036 7
1)
xxii. 1000 91 91 53 53 0.017 6 0.017 7 0.029 1
2) 3)
xxiii. 1200 -- 0.015 1 0.015 1 0.024 7
2) 3)
xxiv. 1400 -- 0.012 9 0.012 9 0.021 2
2) 3)
xxv. 1600 -- 0.011 3 0.011 3 0.018 6
2) 3)
xxvi. 1800 -- 0.010 1 0.010 1 0.016 5
2) 3)
xxvii. 2000 -- 0.009 0 0.009 0 0.014 9
2) 3)
xxviii. 2500 -- 0.007 2 0.007 2 0.012 7
1) These are segmental conductors.
2) Can be either stranded or segmental.
3) The minimum number of wires for these sizes is not specified. These sizes may be constructed
from 4, 5 or 6 equal segments (Milliken).

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S.No. Nominal Minimum Number of Wires in the Maximum Resistance of Conductor at


cross- Conductor 20°C
sectional area Circular conductor Circular Compacted Copper conductor Aluminium
(Non Compacted) or Shaped conductor
conductor
(1) mm2 Cu Al Cu Al Plain wires Tinned /km
(2) (3) (4) (5) (6) /km wires /km (9)
(7) (8)
Note: In case 800 and 1000 square mm if constructed as per segment construction then the minimum,
number of wires is not specified. However, the number of segments can be 4, 5 or 6.

2.4.3 Flexible Conductors (Classes 5 and 6)


Conductor consists of plain or tinned annealed copper.
The wires in the conductor have same nominal
diameter before bunching. The diameter of the wires
in any conductor shall not exceed the appropriate
maximum value given in table 3 for Class 5 & table 4
for Class 6.

Figure 6: Flexible Conductors (Classes 5 and 6)

2.4.4 Comparison of class 2 & Class % conductor


(Ref:- Para 5.8.1 of Section 9 of NEC:023)

While selecting conductor for size less than or equal to 16 sq.mm, copper conductor of Class
1 or Class 2 is recommended.

Description Class 5 Class 2


Size of wire used in sqmm 1.5 1.5
Average length of wire used for wiring in m 1000 1000
Average current in A 5 5
Total running hours per day 10 10
Temperature coefficient of copper 0.00393 0.00393
Reference Temperature deg. C 20 20
Actual Temperature (operating temp) deg. C 30 30
Resistance Ohm/km at actual temperature 14.24 12.68
Energy loss I2Rt in kWh per day 3.56 3.17
Per month loss (kWh) 106.8 95.1
Per year loss (kWh) 1281.6 1141.2
Cost of energy per unit in Rs. 5 5
Cost of energy loss per year in Rs. 6408 5706
Difference (saving if class 2 copper is used) per year in Rs. 702
Price of one coil 1254 1392
Initial investment for wire 12540 13920
Excess amount paid (Additional cost of class 2 wire) 1380
Pay back period in years 2 Years
Resistance Ohm/km at actual temperature 14.24 12.68

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2.5 TYPE OF CIRCUIT


(Ref:- Para 6.4 of Section 9 of NEC:2023)
2.5.1 Lighting Load Circuit
(A) Residential Premises
For the purpose of convenience and redundancy, it is recommended that there shall be
separate/independent circuit/s of lighting load for:
a) All rooms with door where entry can be restricted (attached balcony/terrace may be
included);
b) Common areas like passage, veranda; and
c) Toilets.
Switchboard providing supply exclusively for plug outlets may be provided with separate
circuit.

(B) Non-residential Premises


Circuit design of non-residential premises may be done considering following factors:
a) Enclosed area considering access;
b) Maximum allowable load to suite the assessed current carrying capacity of circuit mains;
c) Utility - light/fan/power outlets; and
d) Routes – ceiling/false ceiling, walls/partitions/under floor raceways.

2.6 TERMINATION OF CIRCUIT INTO SWITCHBOARD


(Ref:-Para 3.5 of CPWD General Specification Part-I & Para 6.3.4.3 of Section 9 of
NEC:2023)
(i) Circuit will consist of phase/neutral/Protective earth wire. Neutral and Earth wire will
terminate in a socket of switch board. Phase/live conductors shall be terminated at the
switch.
NOTE — It is recommended to provide a on board 6A plug socket outlet on every
lighting switchboard which insures availability of neutral and earth, which is required
when additional board/extension is needed in future, which is possible if within limit of
allowable load points on that circuit.
(ii) Light, fans and call bells shall be wired in the ‘lighting’ circuits. 16A socket outlets and
other power outlets shall be wired in the ‘power’ circuits. 6A socket outlets shall also
be wired in the ‘lighting’ circuit both in residential as well as non- residential buildings.
(iii) The wiring throughout the installation shall be such that there is no break in the neutral
wire except in the form of linked switchgear.
(iv) Switches shall be provided on line conductor/phase wires only;
(v) Supply of line conductor to the plug socket on board shall be given through switch and
right side terminal (seen from front) as per convention and neutral shall be connected
left terminal directly;
(vi) Care shall be taken so that neutral does not isolate at places, other than two pole
switch (SPN) which operates simultaneously on both terminals;

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(vii) No part of exposed live part of conductor, solid or stranded (stripped off insulation)
shall remain open outside the area of terminal;
(viii) Cross sectional area of conductor used for inter connections within board shall not be
less than cross sectional area of circuit mains.
(ix) Within switch-board, there shall not be any joints except at terminals.
(x) A low voltage circuit shall be separated from an extra-low voltage circuit.
(xi) Fire alarm and emergency lighting circuits shall be segregated from all other
Conductors and from each other.
(xii) Location of general light and fan switch boards in residential building shall be
positioned close to door frame and on opposite side of hinged edge of door, so that a
person while entering can have immediate access to switch board. If a room has two
doors; lighting control shall be provided on switch boards located near both doors. For
the purpose use of two way switches may be made.

2.7 RUN OF WIRING


(Ref: Para 3.6 of CPWD General Specification Part-I)
i) Surface wiring shall run as far as possible along the walls and ceiling, so as to be easily
accessible for inspection.
ii) Above false ceiling, in no case, open wiring shall be allowed. Wiring will be done in
recessed conduit or surface steel conduit.
iii) In recessed conduit system, routes of conduit will be planned, so that various inspection
boxes provided don’t present a shabby look. Such boxes can be provided 5 mm above
plaster level, and they can be covered with plaster of paris with marking of junction
boxes.
iv) Where number of electrical services like electrical wiring, telephone wiring, computer
cabling, pass through corridors, it may be proper to plan such service with properly
designed aluminium/PVC channels duly covered by a false ceiling, so that subsequently
such service can be maintained and additional Conductors can be provided.
v) Generally, conduits for wiring will not be taken in floor slabs. When it is unavoidable
special precaution to be taken to provide floor channels with provision for safety and
maintenance. Alternatively, false flooring can be provided.
2.7.1 Passing through Walls or Floors
(Ref: Para 3.7 of CPWD General Specification Part-I)

i) When wiring Conductors are to pass through a wall, these shall be taken through a
protection (steel/ PVC) pipe or porcelain tube of suitable size such that they pass through in
a straight line without twist or cross in them on either porcelain, PVC or other approved
material.
ii) All floor openings for carrying any wiring shall be suitably sealed after installation.
2.7.2 Joints in Wiring
(Ref: Para 3.8 of CPWD General Specification Part-I)

i) No bare conductor in phase and/or neutral or twisted joints in phase, neutral, and/ or
protective conductors in wiring shall be permitted.

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ii) There shall be no joints in the through-runs of Conductors. If the length of final circuit or
sub-main is more than the length of a standard coil, thus necessitating a through joint,
such joints shall be made by means of approved mechanical connectors in suitable
junction boxes.
iii) Termination of multi-stranded conductors shall be done using suitable crimping type
thimbles.
Wall Thickness
Walls shall be of sufficient thickness to accommodate concealed boxes/switch
boards/distribution boxes so that installation of boxes do not affect strength of wall.
Additional strengthening shall be considered, if necessary.
NOTE — For example, for 100 mm wall, it is not possible to accommodate boxes of depth
60 mm each back-to-back. Under such cases, staggering may solve problem to certain
extent.

2.8 SOCKET OUTLETS


(Ref: Para 3.11 of CPWD General Specification Part-I)

I. The third pin shall be connected to earth through protective conductor. 2 pin or 5 pin
sockets shall not be permitted to be used.
II. Conductors connecting electrical appliances with socket outlets shall be of flexible type
with an protective conductor for connection to the earth terminal of plug and the metallic
body of the electrical appliance.
III. Sockets for the power outlets of rating above 1KW shall be of industrial type with
associated plug top and controlling MCB.
IV. Where specified, shutter type (interlocking type) of sockets shall be used.
V. Every socket outlet shall be controlled by a switch or MCB, as specified i.e. no direct
socket is permitted. The control switch/MCB shall be connected on the ‘live’ side of the
line.
VI. 6A and 16A socket outlets shall be installed at the following positions, unless otherwise
specified.
a) Non-residential buildings
6A Socket – 110 cm above floor level.
16A Socket – 23/110 cm above floor level.
b) Kitchen – 23 cm above working platform and away from the likely positions of stove
and sink.
c) Bathroom –
6A socket outlet: Socket outlet for portable appliances like hair dryer, shaver etc. to be
provided adjacent to wash basin/ mirror at 110 cm height above floor level.
d) Rooms in residences –
6A Socket – 70 cm above floor level.
6A socket outlet: for other locations, 23 cm/110 cm above floor level, or any other
level in special cases as desired by the Engineer-in-charge.

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e) 16A Socket – 23 cm/110 cm above floor level, or any other level in special cases as
desired by the Engineer-in-charge.
Unless and otherwise specified, the control switches for the 6A and 16A socket outlets shall
be kept along with the socket outlets.

2.9 CONDUIT
2.9.1 Fill factor or space factor
(Ref:- Para 7.2.2.4 of Section 22 of NEC:2023)
Fill factor or space factor is one of the important points strictly to be observed for appropriate
heat dissipation and maintaining temperature within limit for Conductors in enclosures.

NOTE —It shall be noted that number of wires drawn through conduits when exceed allowable
limit, the excess heat generated starts deteriorating insulation very fast leading to
failure and create short circuit. Such work is not easily traceable in external visual
inspection and difficult to correct after the work is complete.
2.9.2 Size of Conduit
(Ref:- Para 5.9.3.6 of Section 9 of NEC:2023)
Size of conduit shall be decided on the basis of number of conductors which can be easily and
safely drawn within, without exceeding the limit of temperature rise (as per below table) at full
load under normal conditions and under that respective situation.

Table 7: Maximum Operating Temperature for Types of Insulation of Cables


(Ref: Table 2 of Section 9 of NEC:2023)

Type of Insulation Temperature Limit (degree C)


Thermoplastic (PVC) 70 at the conductor
Thermosetting (XLPE or EPR rubber) 2)
90 at the conductor
Mineral (thermoplastic (PVC) covered or bare 70 at the sheath
exposed to touch)
Mineral (bare not exposed to touch and not in contact 2),3)
with combustible material) 105 at the sheath
1)
Current carrying capacities are based on temperatures mentioned above or where certified
conductor or cable may have maximum operating temperature limits in accordance with the
manufacturer’s specifications.
2)
Where conductor operates exceeding 70°C, it shall be ascertained that the equipment
connected to the conductor is suitable for the resulting temperature at the connection
3)
For mineral insulated cables higher operating temperature may be possible depending upon
the temperature rating of cable, its terminations, environmental conditions and external
influences.
NOTES
1 Table does not include all types of cables.
2 This does not apply to bus-bar trunking system or power- track system or lighting track
system for which current carrying capacity is provided by manufacturer.
3 For temperature limit of other types of cable please refer cable specifications or

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manufacturer.
For deciding the size of conduit following parameters to be considered like
1. Inside cross-sectional area of conduit
During the checking of size of conduit for number of cables, inside cross-sectional area of
conduit is also important factor. If between pull boxes, for every two deviations in direction
of up to 90 degree, area of conduit shall be considered less by 15 percent. There shall be
no further deviation.

Figure 7: Bends in Conduit

Upper part of figure shows 90° bend and lower part of figure shows four bends each of
45° aggregating to 180°.
2. Cross-sectional area of cables (calculated from the maximum overall diameter including
insulation)
3. Number of cables.
Fill factor shall not exceed values as given below:
a) One conductor 53 percent
b) Two conductors 31 percent
c) Three or more Conductors 40 percent

To find suitable Size of Heavy PVC conduit for number of cables references may be taken
from Table 11 & 12 under Annex II.
2.9.2.1 Example: To find suitable Size of Heavy PVC conduit for:
Number of cables (stranded):
I. 2*1.5 Sq.mm (2 run)
II. 2* 4.0 Sq.mm (1 run)
III. 1* 1.5 Sq.mm (1 run)
Number of bends 2 Nos. of 90°
Cross sectional area of cables from Table 16 of Annex 3
S.N. Class Size of conductor Area of Conductor Number of cable
1 2 1.5 Sq.mm 8.55 Sq.mm 5
2 2 4 Sq.mm 16.62 Sq.mm 2

Fill area = (5*8.55) + (2*16.62) = 75.99 Sq.mm


Since number of cables are 7, Fill factor – 40 percent
Area of Cables = 75.99/0.4 = 189.98 ≈ 190

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Checking of the nearest and next cross sectional area of conduit from Table 15 of Annex 3

S.N. Size of Area of Area after applying Remarks


Conduit Conduit reduction factor 15 percent
since there are 2 bends of
90°
Not Suitable as area
1 20mm 196 Sq.mm 166.60 Sq.mm
less than 190 Sq.mm
Suitable as area higher
2 25mm 333 Sq.mm 283.50 Sq.mm
than 190 Sq.mm

Figure 8: Filling factor in conduit


2.9.3 Number of Wire in Conduit
The maximum number of PVC insulated aluminum/copper conductor of 650/1100 V grade
conforming to IS 694: 1990 that can be drawn in one conduit of various sizes is given in
below Table .Conduit sizes shall be selected accordingly.

Table 8: Maximum Number of PVC Insulated 650/1100 V grade Aluminum / Copper Conductor
conforming to IS 694: 1990
(Ref: Table 4.1 of CPWD General Specification Part-I)

Nominal cross 20mm 25mm 32mm 38mm 51mm 64mm


sectional area of
conductor insq.mm S B S B S B S B S B S B
1 2 3 4 5 6 7 8 9 10 11 12 13
1.50 5 4 10 8 18 12 – – – – – –
2.50 5 3 8 6 12 10 – – – – – –
4 3 2 6 5 10 8 – – – – – –

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Nominal cross 20mm 25mm 32mm 38mm 51mm 64mm


sectional area of
conductor insq.mm S B S B S B S B S B S B
6 2 – 5 4 8 7 – – – – – –
10 2 – 4 3 6 5 8 6 – – – –
16 – – 2 2 3 3 6 5 10 7 12 8
25 – – – – 3 2 5 3 8 6 9 7
35 – – – – – – 3 2 6 5 8 6
50 – – – – – – – – 5 3 6 5
70 – – – – – – – – 4 3 5 4

Note:

(i) The above table shows the maximum capacity of conduits for a simultaneous drawing in
of Conductors.
(ii) The columns headed ‘S’ apply to runs of conduits which have distance not exceeding4.25
m between draw in boxes and which do not deflect from the straight by an angle of more
than 15 degrees. The columns headed ‘B’ apply to runs of conduit, which deflect from the
straight by an angle of more than 15 degrees.
(iii) Conduit sizes are the nominal external diameters.

2.9.4 Fish Wire


To facilitate subsequent drawing of wires in the conduit, GI fish wire of1.6 mm/1.2 mm (16/18
SWG) shall be provided along with the laying of the recessed conduit.
2.9.5 Marking for Non-essential/Essential/UPS/Switch Boards
Each switchboard shall be marked essential/non-essential/UPS to indicate the nature of
such switchboards

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CHAPTER 3 EARTHING

3.1 INTRODUCTION

Neutral of transformer /generator are earthed in electrical distribution system. In addition to


the neutral earthing, provision is made for earthing of MDB, DB& FDB, metallic body of
equipment, Sockets and non-current carrying metallic components in the internal/external
electrical installations.

3.2 EARTHING SYSTEM IN INSTALLATION

Figure 9: Schematic Diagram for TT System in LV Installation

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Figure 10: Schematic Diagram for TN System in LV Installation

A sample schematic Diagram For an Installation has been shown .In this installation incoming
supply from source is coming at incoming of MDB in the installation. Supply is going MDB to
DB & DB to FDB through conductor. Final Circuit is connected from FDB to Load or Switch
Board.

3.3 EATHING ELECTRODE


Separate Earth Electrode to be provided at the starting of Installation i.e. near the MDB. No
earth electrode to be provided Inside the installation. Only protective conductor to be laid
inside the installation

3.4 MAIN EARTHING TERMINAL (MET)


(Ref: para 5.4.2.4 of IS 732:2019)
i In every installation where protective equipotential bonding is used, a main earthing
terminal (MET) shall be provided and the following shall be connected to it:
a. protective bonding conductors
b. earthing conductors
c. protective conductors
d. functional earthing conductors, if relevant.
In above figure MET or earth busbar to be made at MDB. Sub MET to be made at DB &
FDB.

3.5 EARTHING CONDUCTOR


(i) The earthing conductor (protective conductor from earth electrode up to the main
earthing terminal/earth bus, as the case may be) shall be of the same material as the
electrode, viz. GI or copper, and in the form of wire or strip as specified.

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(ii) Earthing conductor’s cross-sectional area shall be not less than 6 mm2 for copper or
50 mm2 for steel when in air.
(iii) Where a bare earthing conductor is buried in the soil, its dimen sions and
characteristics shall also be in accordance with the minimum size required
for earth electrode embedded in soil or concrete
(iv) Aluminium conductors shall not be used as earthing conductors.

3.6 PROTECTIVE CONDUCTOR


3.6.1 Type of Protective Conductor
(Ref: Para 5.4.3.2of IS732:2019)
Protective conductors may consist of one or more of the following:
a. Conductors in multicore cables
b. Insulated or bare conductors in a common enclosure with live conductors
c. Fixed installed bare or insulated conductors
d. Metallic cable sheath, cable screen, cable armour, wire braid, concentric conductor,
metallic conduit

3.6.2 Size of Protective Conductor


(Ref: para 5.4.3.1 of IS 732: 2019)
The cross-sectional areas of protective conductors shall be not less than the below
table:-
Table 9: Minimum Cross-Sectional Area of Protective Conductors (Table 14 of IS 732:2019)
S.N. Cross-sectional Area Minimum Cross Section Area of Protective Conductor mm2
of Line Conductor, S If the protective conductor is of If the protective conductor is
(mm2 Cu) the same not of the same
material as the line conductor material as the line conductor
1 S≤16 S (K1/K2)xS
2 16<S≤35 161 (K1/K2)x16
3 S>35 S1/2 (K1/K2)x(S/2)

Where
k1 = is the value of k for the line conductor selected from Tables 58 to Table 62 of IS 732:
2019 as applicable, according to the materials of the conductor and insulation;
k2 = is the value of k for the protective conductor, selected from Tables 58 to Table 62 of IS
732: 2019 as applicable.
1) For a PEN conductor, the reduction of the cross-sectional area is permitted only in
accordance with the rules for sizing of the neutral conductor
Cross sectional Area of protective conductor for Final or Standard Circuit already
given in table-2.

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3.6.3 Example
Table 10: Size of GI Protective Conductor for 16Sqmm & 10Sq.mm Aluminum & Copper Cable

S.N. Type of Cross- Minimum Cross Section Area of Protective Conductor sq.mm Reference
cable sectional
Area of If the
If the Minimum Cross Section Area of Protective
Phase protective
protective Conductor If the protective conductor is
Cable conductor
conductor not of the same material as the line
is of the
is not of conductor
same
the same
material
material
as the line
as the line
conductor
conductor
PVC/XLPE (Sq.mm) Type of K1K2 K1/K2 Formula for Value of Minimum
Copper/ Protective Area of GI Area of Size of
Aluminum Conductor (Sq.mm) GI GI wire
(Sq.mm) (In mm)
1 PVC 10 10 Sq.mm 11558 1.98 (K1/K2)x10 19.83 4.88 Table-
insulated PVC Bare GI 58
copper insulated wire in
Cable copper Contact
Cable with
Cable
Covering
2 XLPE 16 16 Sq.mm but not 9450 1.88 (K1/K2)x16 30.08 6.40 Table-
insulated XLPE Bunched 58
Aluminium insulated with Other
Cable Aluminium Cables
Cable
3 PVC 25 16 Sq.mm GI armour 11551 2.25 (K1/K2)x16 36.08 7.01 Table-
insulated PVC 61
copper insulated
Cable copper
Cable
4 XLPE 35 16 Sq.mm GI armour 9446 2.04 (K1/K2)x16 32.70 6.40 Table-
insulated XLPE 61
Aluminium insulated
Cable Aluminium
Cable
3.6.4 Connection of Protective Conductor
(i) All protective conductors of Final circuit (FDB to Load or switch board) to be connected
at Sub MET of FDB.
(ii) All protective conductors from DB to FDBs to be connected at Sub MET of DB and
each FDB.

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(iii) All protective conductors from MDB to DBs to be connected at MET of MDB and sub
MET of each FDB.
(iv) Protective Conductor from body of MDB,DB & FDB to be connected MET & sub MET of
respectively MDB/DB/FDB
(v) Earthing conductor to be connected

3.7 TYPE OF SYSTEM EARTHING


Check type of system earthing i.e. TN-C, TN-CS, TN-S, TT or IT.
3.7.1 TT System
Generally, in TT systems, following protective devices shall be used for earth fault protection
Final Distribution board (FDB):- 30mA Current Operated RCCB
Main Distribution board (MDB):- 300mA Current Operated RCCB
3.7.2 TN System
(Ref: Para MM 6.2.3.6.2 of Annexure-MM of IS 732: 2019)

The tripping of MCB during short circuit/Earth fault depend on the value of Loop Impedance
encountered by the fault current. The relation between tripping current (It) of MCB and the
maximum earth fault/short circuit loop impedance (Zs) of the concern circuit are as below:
2 𝑈
Zs≤ 3 ( 𝐼 0 )
𝑡

The maximum fault loop impedance in (Ω) of the concern circuit. Its comprising:
a) The source,
Zs
b) The line conductor up to the point of the earth fault/short circuit, and
c) The protective conductor between the point of the fault and the source;
The current in amperes (Amp.) causing the automatic operation of the disconnecting
It
device (MCB) within the time (0.1 sec)
U0 The nominal A.C. or D.C. line to earth voltage in volts (V).

Table 11: Maximum Earth fault/ Short circuit Loop Impedance Values for Tripping of MCB’s
under Earth Fault/ Short Circuit
Type MCB 6 10 16 20 25 32 40 50 63 80 100 125
of rating
MCB in Amps
B Zs(In
Ohms)
5.11 3.07 1.92 1.53 1.23 0.96 0.77 0.61 0.49 0.38 0.31 0.25
=(2/3x
(U0/ It)
C Zs(In
Ohms)
2.56 1.53 0.96 0.77 0.61 0.48 0.38 0.31 0.24 0.19 0.15 0.12
=(2/3x
(U0/It)

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D Zs(In
Ohms)
1.28 0.77 0.48 0.38 0.31 0.24 0.19 0.15 0.12 0.10 0.08 0.06
=(2/3x
(U0/ It)

3.8 APPLICATION FOR INTERNAL E.I.


(Ref: Para 8.2.2(K) of CPWD General Specification Part-I)

Application for Internal E.I.:

(i) Every sub-main will have protective conductor that run along with sub-main wiring. In
case of 3- phase sub-main wiring to the final equipment, two protective conductors shall
be provided to make connection to protective equipotential bonding.

(ii) Every circuit will have its protective conductor running along with circuit wiring. In case of
3-phase circuit to final equipment, two protective conductors shall be provided.

(iii) Looping of earth is allowed only in case of point wiring for light fittings and sockets.
Looping is not allowed for wiring in the final circuits for electronic installations such as
computers and equipment with SMPS power supply.

(iv) When 2/3 power outlets are looped to one circuit, earth looping of these outlets is
permissible.

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CHAPTER 4 DO’S & DON’Ts FOR WIRING GUIDELINES

Detail of Do’s and Don’ts for supply and installation of MDB (Main Distribution Board),DB
(Distribution Board),FDB (Final Distribution Board),Final Circuit & Conduit are as below:

4.1 MAIN DISTRIBUTION BOARD


Detail of Do’s and Don’ts for supply and installation of MDB (Main Distribution Board) ,DB
(Distribution Board) ,FDB (Final Distribution Board),Final Circuit & Conduit are as below:

4.1.1 MAIN DISTRIBUTION BOARD


Do’s Don’ts

1. There shall clear space of at least 1m in width in 1. Don’t connect cable to


front of distribution board is required for ease of MCCB/MCB without proper
working.
lug/ thimble
2. In case of floor mounted panel space at the back
of the distribution board shall either be less than 2. No open dummy hole in in
20 cm (for no accessibility) or more than 75 cm Main distribution board
(for accessibility) in width.
3. Don’t Installed Main
3. If back space is more than 75 cm then it should distribution board under lock
be open at both ends upto a height of 180 cm. condition.
4. In front of panel there shall be an insulating floors
or class A mats conforming to IS 15652. 4. No common neutral and earth
conductor shall be used for
5. There shall be adequate illumination and multiple outgoing circuits.
ventilation at locations where MDB panel are
installed for ease of maintenance. 5. Twisted joints for making
6. Proper rating Earth Busbar to be provided in MDB multiple neutral or earth should
not be done.
7. Earth Busbar from MDB to be connect Earth
Electrode. 6. Cable connected to Switchgear
8. All Outgoing Protective Earth Wire to be connect shall not be stressed condition
to Earth bus bar of MDB
9. DO's the affix permanently in a visible position a
danger notice in Hindi or English and local
language
10. Gasket to be provided
11. Spreader link to be provided with MCCB
12. If MCCBs are adjustable then setting of MCCB to
be ensured.
13. IP protection should be ensured for outdoor
installation

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4.1.2 DISTRIBUTION BOARD


Do’s Don’ts
1. Colour coding to be ensured, For Three 1. Don’t connect cable to MCCB/MCB
Phase - Red/ Yellow/Blue, Neutral - Black, without proper lug/ thimble.
PE – Green-Yellow, for single phase – Red, 2. No open dummy hole in distribution
Neutral black, PE – Green-Yellow. board.
2. Height of DB shall be above ground such 3. Don’t Install distribution boards in
that it is beyond the reach of children. An locked locations.
average height is between 1.8 to 2.1m.
4. No common neutral and earth
3. Capacity of Bus bar (if provided) should be conductor shall be used for multiple
equal to or more than rating of incoming outgoing circuits.
MCB/MCCB of DB.
5. Twisted joints for making multiple
4. Neutral conductor to be connected to neutral or earth should not be done.
neutral bus bar of DB.
6. Cable connected to Switchgear shall
5. Incoming & outgoing protective earthing not be stressed condition.
conductors shall be connected to Earth bus
bar of DB.
6. Proper labelling should be done in DB.
7. Rating of outgoing MCB in DB should be
equal to or more than incoming MCB at
FDB.
8. Spare MCB to be provided as per
requirement of future expansion.
9. Rubber Gasket to be provided in DB
10. Suitable IP protection should be ensured for
outdoor installations.
11. Cable armour to be connected to DB
through gland
12. Cable to be provided with suitable glands.

4.1.3 FINAL DISTRIBUTION BOARD


Do’s Don’ts
1. Colour coding to be ensured. For Phase - 1. Don’t connect cable to MCB without
Red, Neutral - Black, PE – Green-Yellow. proper lug/ thimble.
2. Location of FDB shall be at load centre to 2. No open dummy hole in Final
limit circuit mains and voltage drop. distribution board.
3. Height of FDB shall be above ground such 3. Don’t Install Final distribution boards
that it is beyond the reach of children. An in locked locations.
average height is between 1.8 to 2.1m. 4. No common neutral and earth
4. Capacity of Bus bar phase link for phase conductor shall be used for multiple
should be as per for equal to or more than outgoing circuits.

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Do’s Don’ts
rating of incoming MCB of FDB. 5. Cable to be provided with suitable
glands.
5. Neutral wire conductor to be connected to
neutral bus bar of FDB. 6. Twisted joints for making multiple
neutral or earth outgoing should not
6. Proper labelling should be done in FDB.
be done.
7. 30 mA RCCB to be provided for shock
7. Cable connected to Switchgear shall
protection. 30 mA suitable rating RCBO can
not be stressed condition.
be provided in place of MCB & RCCB.
8. If outgoing circuits are more, then
sectionization of circuits may be done and
30 mA RCCB may be provided for each
section to avoid nuisance tripping due to
inherent leakage current in electrical
equipment.
9. Gasket should be provided in FDB.
10. Phase link for outgoing MCBs to be
provided in FDB
11. As per requirement spare MCB to be
provided.
12. Incoming & outgoing protective earth
conductors shall be connected to Earth bus
bar of FDB

4.1.4 FINAL CIRCUITS

Do’s Don’ts
1. Class 2 copper conductor is recommended 1. 2pin/plate ceiling rose should not
for fixed wiring. be used instead 3 pin/plate
2. Colour coding to be ensured. For Phase - 2. Don’t use higher rating 16/ 20A C
Red, Neutral - Black, PE – Green-Yellow. type MCB for lighting & power
3. General height of switch board should be circuits
reachable and 1.2 m above ground level. 3. Don’t use 5 pin& 2 pin sockets.
4. Separate neutral and protective earth 4. Don’t terminate conductors without
conductor to be used from FDB (From thimbles.
Neutral & Earth Busbar)
5. Rating of MCB should be as per connected
load.
6. Rating of MCB & size of line wire should be
properly coordinated for overload protection.
7. Size of protective earth wire should be same
as per Line wire.
8. Plug Socket outlet boards shall be located as
near as possible from the location of

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appliance to avoid mess of loose cords.


9. If position of switch-board is above top of
table/platform; it shall be 150 mm above the
surface of table/platform top
10. Plug outlets if required at lower level shall be
200 mm above finished floor level and such
plug sockets must be shuttered type

4.1.5 CONDUITS
Do’s Don’ts
1. Within conduit system, there shall be
1. Fixing of conduit on surface may be done with
no sharp edges, burrs or surface
saddle/saddle with spacer/clips.
projections which may damage
2. Size of conduit shall be decided on the basis of insulated conductor/cable or inflict
number of cables which can be easily and injury to the installer or user
safely drawn within, without exceeding the limit
of temperature rise 2. Don’t use of metal conduits as earth
continuity conductor shall not be
permitted in general.

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Annexure 1

Different Correction Factor to be applied to the Current-Carrying Capacities for


Cables

Table 12: Correction Factor for Ambient Air Temperatures Other Than 30 °C to be applied to the
Current-Carrying Capacities for Cables in the Air

(Ref: Table 33 of IS 732:2019)

Insulation
Mineral 1)
Ambient
Temperature °C PVC XLPE and EPR PVC Covered or Bare not Exposed to
Bare and Exposed Touch 105 °C
to Touch 70 °C
(1) (2) (3) (4) (5)
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
25 1.06 1.04 1.07 1.04
30 1.00 1.00 1.00 1.00
35 0.94 0.96 0.93 0.96
40 0.87 0.91 0.85 0.92
45 0.79 0.87 0.78 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 the manufacturer

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Table 13: 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

(Ref: Table 34 of IS 732:2019)

Ground Temperature Insulation


°C PVC XLPE and EPR
(1) (2) (3)
10 1.10 1.07
15 1.05 1.04
20 1.00 1.00
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

Table 14: Reduction Factors for One Circuit or One Multi-core Cable or for a Group of more than One
Circuit, or more than one multi-core cable
(Ref: Table 36 of IS 732:2019)

To be Used
Arrangement Number of Circuits or Multi-core Cables with
Item (Cables Current-
Touching) Carrying
Capacities,
Reference
1 2 3 4 5 6 7 8 9 12 16 20
1 Bunched in air, 1.0 0.8 0.70 0.65 0.60 0.5 0.54 0.52 0.50 0.4 0.41 0.38 Tables 21
on a surface, 0 0 7 5 to 32
embedded or Methods A
enclosed to F
2 Single layer 1.0 0.8 0.79 0.75 0.73 0.7 0.72 0.71 0.70
on wall, floor 0 5 2
No further Tables 21
or to 26
unperforated reduction

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cable tray factor for Method


systems more than C
nine circuits
3 Single layer 0.9 0.8 0.72 0.68 0.66 0.6 0.63 0.62 0.61 or multicore
fixed 5 1 4 cables
directly
under a
wooden
ceiling
4 Single layer 1.0 0.8 0.82 0.77 0.75 0.7 0.73 0.72 0.72
on a 0 8 3
Tables 27 to
perforated 32 Methods
horizontal or E and F
vertical cable
tray systems
5 Single layer 1.0 0.8 0.82 0.80 0.80 0.7 0.79 0.78 0.78
on cable 0 7 9
ladder
systems or
cleats etc.,
NOTES
1. These factors are applicable to uniform groups of cables, equally loaded.
2. Where horizontal clearances between adjacent cables exceeds twice their overall diameter, no
reduction factor need be applied.
3. The same factors are applied to:
a. groups of two or three single-core cables;
b. multi-core cables.
4. If a system consists of both two- and three-core cables, the total number of cables is taken as the
number of circuits, 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.
5. 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.
6. The values given have been averaged over the range of conductor sizes and types of installation
included in Tables 21 to Table 32 the overall accuracy of tabulated values is within 5 percent.
7. 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, see for example, Table 39 and Table 40.

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Annexure 2
Table 15: Current-Carrying Capacity (in Amperes) of PVC and XLPE cable
(Normative)
(Ref: Table 41 of Annex-T of IS 732:2019)
Reference Number of Loaded Conductors and Types of Insulations
methods in
Table 20 of
IS:732:2019

A1 3PVC 2PVC 3XLPE 2XLPE


A2 3PVC 2PVC 3XLPE 2XLPE
B1 3PVC 2PVC 3XLPE 2XLPE
B2 3PVC 2PVC 3XLPE 2XLPE
C 3PVC 2PVC 3XLPE 2XLPE
E 3PVC 2PVC 3XLPE 2XLPE
F 3PVC 2PVC 3XLPE 2XLPE
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
2
Size (mm )
Copper
1.5 13 13.5 14.5 15.5 17 18.5 19.5 22 23 24 26 --
2.5 17.5 18 19.5 21 23 25 27 30 31 33 36 --
4 23 24 26 28 31 34 36 40 42 45 49 --
6 29 31 34 36 40 43 46 51 54 58 63 --
10 39 42 46 50 54 60 63 70 75 80 86 --
16 52 56 61 68 73 80 85 94 100 107 115 --
25 68 73 80 89 95 101 110 119 127 135 149 161
35 -- -- -- 110 117 126 137 147 158 169 185 200
50 -- -- -- 134 141 153 167 179 192 207 225 242
70 -- -- -- 171 179 196 213 229 246 268 289 310
95 -- -- -- 207 216 238 258 278 298 328 352 377
120 -- -- -- 239 249 276 299 322 346 382 410 437
150 -- -- -- -- 285 318 344 371 395 441 473 504
185 -- -- -- -- 324 362 392 424 450 506 542 575
240 -- -- -- -- 380 424 461 500 538 599 641 679
Aluminium
2.5 13.5 14 15 16.5 18.5 19.5 21 23 24 26 28 --
4 17.5 18.5 20 22 25 26 28 31 32 35 38 --
6 23 24 26 28 32 33 36 39 42 45 49 --
10 31 32 36 39 44 46 49 54 58 62 67 --

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16 41 43 48 53 58 61 66 73 77 84 91 --
25 53 57 63 70 73 78 83 90 97 101 108 121
35 -- -- -- 86 90 96 103 112 120 126 135 150
50 -- -- -- 104 110 117 125 136 146 154 164 184
70 -- -- -- 133 140 150 160 174 187 198 211 237
95 -- -- -- 161 170 183 195 211 227 241 257 289
120 -- -- -- 186 197 212 226 245 263 280 300 337
150 -- -- -- -- 226 245 261 283 304 324 346 389
185 -- -- -- -- 256 280 298 323 347 371 397 447
240 -- -- -- -- 300 330 352 382 409 439 470 530
Note: (i)The appropriate table of current carrying capacity given in Annexure S of IS-732:2019 should be
consulted to determine the range of conductor sizes for which the above current carrying capacities are
applicable, for each installation method.
(ii) For the time being, this Annex relates to non armoured cables and insulated conductors having a nominal
voltage not exceeding 1 kV a.c. or 1.5 kV d.c. This Annex may be applied for armoured multi-core cables
but does not apply to armoured single-core cables.

Table 16: Reduction factor in D1/D2 installation


(Normative)

(Ref: Table 42 of Annex-T of IS 732:2019)


Installation Size in sq.mm Number of Loaded Conductors and Type of Insulation
Method 2PVC 3PVC 2XLPE 3XLPE
D1/D2 Copper
1.5 22 18 26 22
2.5 29 24 34 29
4 38 31 44 37
6 47 39 56 46
10 63 52 73 61
16 81 67 95 79
25 104 86 121 101
35 125 103 146 122
50 148 122 173 144
70 183 151 213 178
95 216 179 252 211
120 246 203 287 240
150 278 230 324 271
185 312 258 363 304
240 361 297 419 351
300 408 336 474 396
Aluminum
D1/D2 2.5 22 18.5 26 22
4 29 24 34 29

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6 36 30 42 36
10 48 40 56 47
16 62 52 73 61
25 80 66 93 78
35 96 80 112 94
50 113 94 132 112
70 140 117 163 138
95 166 138 193 164
120 189 157 220 186
150 213 178 249 210
185 240 200 279 236
240 277 230 322 272
300 313 260 364 308

Annexure 3
Dimension of Non-Metallic Conduits (PVC) & Single Core Non-Sheathed Cables with
Rigid Conductor Class 1 or Class 2

Table 17: Dimension of Non-Metallic Conduits (PVC)


(Ref: Table D-3 of Annexure D of Section 9 Part-1 of NEC-2023)
Note: For more information, refer 7.1 of IS 9537 (Part2): 1981
Sr. Nominal Outside Light (LMS) Medium (LMS) Heavy (LMS)
No. size diameter Min. Cross Min. Cross Min. Cross
inside sectional inside sectional inside sectional
diameter area diameter area diameter area
i. 16 16 13.7 147 13.0 133 12.2 117
ii. 20 20 17.4 238 16.9 224 15.8 196
iii. 25 25 22.1 384 21.4 360 20.6 333
iv. 32 32 28.6 642 27.8 607 26.6 556
v. 40 40 35.8 1007 35.4 984 34.4 929
vi. 50 50 45.1 1598 44.3 1541 43.2 1466
vii. 63 63 57.0 2552

Table 18: Dimensions of Single Core Non-Sheathed Cables with Rigid Conductor Class 1 or
Class 2
(Ref: Table D-4 of Annexure D of Section 9 Part-1 of NEC-2023)
Notes
1 For more information, refer 16.1.2 and 16.1.3 of IS 694:2010.
2 Class 1 is solid conductor and class 2 is stranded conductor, for further details, refer Table
3 of IS 694.
Sr. Nominal Sectional area Class of Thickness Maximum Cross sectional
No. of conductor conductor of insulation overall diameter area of cable
mm2 mm mm mm2
i. 0.5 1 0.6 2.3 4.15
ii. 0.75 1 0.6 2.5 4.91
iii. 1 1 0.6 2.7 5.73

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iv. 1.5 1 0.7 3.2 8.04


v. 1.5 2 0.7 3.3 8.55
vi. 2.5 1 0.8 3.9 11.95
vii. 2.5 2 0.8 4 12.57
viii. 4 1 0.8 4.4 15.21
ix. 4 2 0.8 4.6 16.62
x. 6 1 0.8 5 19.64
xi. 6 2 0.8 5.2 21.24
xii. 10 1 1 6.4 32.17
xiii. 10 2 1 6.7 35.26
xiv. 16 2 1 7.8 47.78
xv. 25 2 1.2 9.7 73.90
Annexure-4
VALUE OF K1 & K2
Table 19: Values of k1 for Conductors
(Ref.: Table 3 of IS 732: 2019)

Property/ Condition Type of Conductor Insulation


PVC PVC EPR XLPE Rubber 60°C Mineral
Thermoplastic Thermoplastic Thermosetting thermosetting PVC Bare
90° C sheathed unsheathed
Conductor cross-sectional
300 >300 300 >300
area mm2
Initial temperature °C 70 90 90 60 70 105
Final temperature °C 160 140 160 140 250 200 160 250
Conductor material
Copper 115 103 100 86 143 141 115 135-1151)
Aluminium 76 68 66 57 94 93 -- --
Tin- soldered joints in
115 -- -- -- -- -- -- --
copper conductors
1)
This value shall be used for bare cables exposed to touch.
Notes
1 Other values of k are under consideration for:
- small conductors (particularly for cross-sectional areas less than 10mm2)
- other types of joints in conductors
- bare conductors
2 The nominal current of the short-circuit protective device may be greater than the current-carrying capacity of the cable.
3 The above factors are based on IEC 60724.
4 See Annex EE (5.4) for the calculation-method of factor k.

Table 20: Values of k2 for Insulated Protective Conductors not Incorporated in Cables and not
Bunched with other cables
(Ref.: Table 58 of IS 732: 2019)

Temperature Material of conductor


Conductor insulation Copper Aluminium Steel
Initial Final
Values for k 3)

70°C thermoplastic (PVC) 30 160/ 140 1)


143/ 133 1)
95/ 881) 52/ 491)

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90°C thermoplastic (PVC) 30 160/ 1401) 143/ 1331) 95/ 881) 52/ 491)
90°C thermosetting (e.g. XLPE and EPR) 30 250 176 116 64
60°C thermosetting ( EPR rubber) 30 200 159 105 58
85°C thermosetting EPR rubber 30 220 166 110 60
185°C thermosetting (silicon rubber) 30 350 201 133 73
1)
The lower value applies to thermoplastic (for example, PVC) insulated conductors of cross-sectional area greater than
300mm2.
2)
Temperature limits for various types of insulation are given in IEC 60724.
3)
For the method of calculating k, see the formula at the beginning of this Annex.

Table 21: Values of k2 for Bare Protective Conductors in Contact with Cable Covering but not
Bunched with other Cables
(Ref.: Table 59 of IS 732: 2019)

Temperature °C1) Material of conductor


Cable covering Copper Aluminium Steel
Initial Final
Values for k2)
30 200 159 105 58
3)
Thermoplastic (PVC) polyethylene CSP 30 150 138 91 50
30 220 166 110 60
1)
Temperature limits for various types of insulation are given in IEC 60724
2)
For the method of calculating k, see the formula at the beginning of this Annex.
3)
CSP = Chloro - Sulphonated Polyethylene

Table 22: Values of k2 for Insulated Protective Conductors as a core Incorporated in a Cable or
Bunched with other cables or Insulated Conductors
(Ref.: Table 60 of IS 732: 2019)

Conductor insulations Temperature °C2) Material of conductor


Initial Final Copper Aluminium Steel
Values for k 3)

70°C thermoplastic (PVC) 70 160/ 1401) 115/ 1031) 76/ 681) 42/ 371)
90°C thermoplastic (PVC) 90 160/ 1401) 100/ 861) 66/ 571) 36/ 311)
90°C thermosetting (e.g. XLPE and EPR) 90 250 143 94 52
60°C thermosetting (rubber) 60 200 141 93 51
85°C thermosetting rubber 85 220 134 89 48
185°C thermosetting (silicon rubber) 180 350 132 87 47
1)
The lower value applies to thermoplastic (for example, PVC) insulated conductors of cross-sectional area greater than
300mm2.
2)
Temperature limits for various types of insulation are given in IEC 60724.
3)
For the method of calculating k, see the formula at the beginning of this Annex.

Table 23: Values of k2 Protective Conductors as a Metallic Layer if a Cable, for example, Armour,
Metallic sheath, Concentric conductor, etc.
(Ref.: Table 61 of IS 732: 2019)

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SAFETY IN ELECTRICAL LOW VOLTAGE INSTALLATIONS

Conductor insulations Temperature °C1) Material of conductor


Initial Final Copper Aluminium Steel
Values for k 3)

70°C thermoplastic (PVC) 60 200 141 93 51


90°C thermoplastic (PVC) 80 200 128 85 46
90°C thermosetting (e.g. XLPE and EPR) 80 200 128 85 46
60°C thermosetting (rubber) 55 200 144 95 52
85°C thermosetting rubber 75 220 140 93 51
Mineral thermoplastic (PVC) covered 2)
70 200 135 -- --
Mineral bare sheath 105 250 135 -- --
1)
Temperature limits for various types of insulation are given in IEC 60724.
2)
This value shall also be used for bare conductors exposed to touch or in contact with combustible material.
3)
For the method of calculating k, see the formula at the beginning of this Annex.

Table 24: Values of k2 for Bare Conductors where there is no risk of damage to any neighbouring
material by the temperature indicated
(Ref.: Table 62 of IS 732: 2019)

Initial Material of conductor


Conditions
temperature Copper Aluminium Steel
Maximum Maximum Maximum
Temperature Temperature Temperature
k k k
(Final (Final (Final
value value value
temperature) temperature) temperature)
°C °C °C °C
Visible and in
30 500 228 300 125 500 82
restricted area
Normal conditions 30 200 159 200 105 200 58
Fire risk 30 150 138 150 91 150 50

40 Vol.9: DESIGN GUIDELINES FOR ELECTRICAL WIRING INSTALLATIONS


SAFETY IN ELECTRICAL LOW VOLTAGE INSTALLATIONS

Annexure 5
DETAIL WIRING DIAGRAMS FROM MDB TO FINAL CIRCUIT

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42 DESIGN GUIDELINES FOR ELECTRICAL WIRING INSTALLATIONS


SAFETY IN ELECTRICAL LOW VOLTAGE INSTALLATIONS

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44 DESIGN GUIDELINES FOR ELECTRICAL WIRING INSTALLATIONS


SAFETY IN ELECTRICAL LOW VOLTAGE INSTALLATIONS

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46 DESIGN GUIDELINES FOR ELECTRICAL WIRING INSTALLATIONS


SAFETY IN ELECTRICAL LOW VOLTAGE INSTALLATIONS

Description
1 MDB (Main Distribution Board 8 MET (Main Earth Bus Bar)
2 4P Incoming MCCB 9 Incoming 4 Core Cable
3 4P outgoing MCCB 10 Protective Earthing Conductor (Cable Armoured)
4 Phase Bus Bar (Main) 11 Outgoing 4 core Cable
5 Neutral Bus Bar (Main) 12 Protective Earthing Conductor
6 Earth Electrode 13 Gland
7 Earthing Conductor

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NOTE
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48 VOLUME 8: DESIGN GUIDELINES FOR ELECTRICAL WIRING INSTALLATIONS


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CONTACT US

CAMTECH is continuing its efforts in the documentation and up-gradation of information on


maintenance practices of electrical assets. Over the years a large number of publications on electrical
assets have been prepared in the form of handbooks, pockets books, pamphlets and video films, etc.
These publications have been uploaded on the internet as well as rail net.

Link for downloading CAMTECH publications:

On internet visit: https://indianrailways.gov.in/


Or
On Railnet visit Railway Board website at http://10.1.2.21/

Go to Indian Railways  Directorates  Efficiency & Research  CAMTECH, Gwalior 


Publications for download
Or
Link for directly download the Publications:

https://indianrailways.gov.in/railwayboard/view_section.jsp?lang=0&id=0,1,304,366,538,2713,2718
,2722

Dy. Director (Elect.) BSNL : 0751- 2470740 (O)

Rly. : 03747202, 9752447030 (CUG)

SSE/Electrical : 9755549297 (CUG)

E-mail : [email protected]

Fax : 0751- 2470841

Write at : Dy. Director (Electrical)

Indian Railways, Centre for Advanced Maintenance Technology


In front of Hotel Adityaz, Airport Road, Maharajpura, Gwalior, Pin code – 474 005

VOLUME 8: DESIGN GUIDELINES FOR ELECTRICAL WIRING INSTALLATIONS


SAFETY IN ELECTRICAL LOW VOLTAGE INSTALLATIONS

INDIAN RAILWAYS
Centre for Advanced maintenance TECHnology (CAMTECH), Maharajpura, Gwalior - 474005
50 VOLUME 8: DESIGN GUIDELINES FOR ELECTRICAL WIRING INSTALLATIONS

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