CASTLINE SYSTEMS

CABLECALC version 3

FOR WINDOWS
Copyright © 1999 Castline Systems All rights reserved
Microsoft is a registered trademark of Microsoft Corporation.
Windows is a registered trademark of Microsoft Corporation.
All other registered trademarks are acknowledged.
References
Requirements for Electrical Installations IEE Wiring Regulations Sixteenth Edition BS7671 : 1992 Incorporating Amendment No. 1, 1994 (AMD
8536).
IEE Inspection & Testing Guidance Notes 3
Protection Against Electric Shock IEE 16th Edition Wiring Regulations Guidance Notes Number 5 in a series
Castline Systems reserve the right to change specifications without notice.

Castline Systems,
Welford House, 39 Alfriston Road,
Worthing, West Sussex, BN14 7QS,
United Kingdom.
Telephone 01903 201837
Contents
Overview 7
About This Reference ............................................................................... 7
Use of Cablecalc for Windows...................................................... 7
About Cablecalc for Windows .................................................................. 7

Getting Started 9
Installation................................................................................................ 9
Starting Cablecalc..................................................................................... 9
Windows 95 or 98......................................................................... 9
Before you begin .................................................................................... 10
Help............................................................................................ 10
Starting Cablecalc................................................................................... 10
Starting Cablecalc ....................................................................... 10
Starting a Calculation.................................................................. 10
Saving Your Work (levels 2-3-4) ................................................ 11
Setting Your Printer .................................................................... 11
Printing Reports.......................................................................... 11
Correcting Calculation Errors ................................................................. 12
Hint Button................................................................................. 12
Viewing the sample file .......................................................................... 12
Setting up a Project File.......................................................................... 13
Project Default Values............................................................................ 13
Create Distribution Boards ..................................................................... 14
Create Distribution board ............................................................ 14
Formulae and Conversion ....................................................................... 15

The Cable Calculator 17

Tab 1 - Supply........................................................................................ 17
To calculate and save a cable ...................................................... 17
Type of Circuit:........................................................................... 17
Diversity ..................................................................................... 19
Tab 2 - Cables ........................................................................................ 20
Tab 3 - Protection ................................................................................... 21
Overload / short circuit protection ............................................... 21
Type of circuit............................................................................. 21
Select Protective Device.............................................................. 21
Tab 4 – Derating..................................................................................... 23
Thermal insulation (Ci) ............................................................... 23
Tab 5 - CPC Details................................................................................ 25
Select CPC.................................................................................. 25

CASTLINE SYSTEMS CableCalc • 5

 Tab 6 - Calculate .....................................................................................27
Cable Size....................................................................................27
Volt Drop ....................................................................................27
Impedance ...................................................................................28
Calculation related problems ...................................................................28
1.) Cable Size...............................................................................28
2.) Volt Drop ...............................................................................29
3.) Impedance ..............................................................................29

The Project Manager 31

The Project Manager ...............................................................................31
Buttons ........................................................................................32
Menus..........................................................................................33
Projects: A beginners guide. ....................................................................34
1) Create Project file ....................................................................35
2) Create Distribution board within the project file.......................35
3) Save a circuit within the Distribution board file. ......................36
To calculate and save a cable...................................................................37
To calculate a cable......................................................................37
To calculate a sub main cable.......................................................37

Utilities 39
The Time Curve Utility. ..........................................................................39
The menus ...................................................................................39
The Conduit Utility..................................................................................42
The menus ...................................................................................42
The Trunking Utility................................................................................44
The menus ...................................................................................44
The Diversity Utility................................................................................45
The menus ...................................................................................46

Trouble Shooting 49
Version....................................................................................................49
Where to look for answers .......................................................................49
Computer Related Problems ....................................................................49
Operation problems .................................................................................51
Error codes ..................................................................................51

Glossary of Terms 53

CASTLINE SYSTEMS CableCalc • 6

Overview

About This Reference

This reference is a guide to the use of the Cablecalc for Windows programme, and covers the
general aspects of operating the various features available. It does not profess to be a Windows
Tutorial. However, some points essential to the operation of the programme will be covered.

Use of Cablecalc for Windows

Cablecalc for Windows is for use by electrical contractors, electrical engineers and consultants
that possess a good general knowledge of the electrical design and installation trade. Many of
the terms and descriptions used in Cablecalc for Windows will be very obvious to them, but
will be meaningless to any non electrical users of the programme. We must stress that
Cablecalc for Windows is not a magic wand for creating electrical design engineers and
emphasise that the experience and judgement of the competent electrical engineer conversant
with the IEE Wiring Regulations will greatly enhance the use of this programme.

About Cablecalc for Windows

Cablecalc for Windows is designed to produce cable sizing and circuit evaluation data to
comply with the IEE Wiring Regulations, Requirements for Electrical Installations (BS 7671 :
1992) incorporating amendment No. 1, 1994 (AMD 8536). Reports may be printed on any
printer supported by Microsoft Windows, and may also be stored on disc and recalled later for
updating (as well as ease of generating file copies for office use).
NOTE: Cablecalc for Windows version 3 levels 2 – 3 & 4 will export circuit data to FormFill for Windows versions 2 and 3.

All software supplied by Castline Systems has been fully checked for all known viruses before
dispatch. Please note that all Castline Systems software has the name of the licensed user
embedded into the code. Should the software detect that it has been installed incorrectly (or
that no company name has been entered) then it will operate in Unregistered Demonstration
mode only.

Cablecalc ‘Plus’ for Windows (level 2) provides an invaluable set of additional utilities
offering the following additional features:-

• Time Curve
• Conduit
• Trunking
• Diversity
• Distribution board schedules

CASTLINE SYSTEMS Cablecalc Overview • 7

 • Formulae and conversions
• Lighting circuit calculations
• Busbar trunking calculations

Cablecalc ‘Elite’ for Windows (level 3) provides the following additional features:-

• Phase balance graphs

• Schematic diagrams
• Circuit charts
• Multiple circuit calculations

Cablecalc ‘Professional’ for Windows (level 4) provides the following additional features:-

• Single Line Diagrams

• Schematic diagrams
• Cost details

CASTLINE SYSTEMS Cablecalc Overview • 8

Getting Started

Installation
To install Cablecalc for Windows Version 3, place the CD in your CD-ROM drive and click
start, then run, then type D:\setup and click ok. Cablecalc will be installed to C:\program
files\Cablecalc.

It is recommend that your computer is set for a resolution of 1024 x 768 or greater and
recommend a minimum requirement of 640 x 480.

Starting Cablecalc

Windows 95 or 98
To run the programme from Windows 95 or Windows 98:
To run the programme from the ‘Start’ Button

• Click the ‘Start’ button

• Select ‘programs’
• Select ‘Castline’.
• Select ‘Cablecalc’.

To run the programme from the Castline Program Group

• Double click on the Cablecalc for Windows icon in the Castline Program Group

It is recommended that the screen resolution be set to 1024 x768. However the programme will
work in 640 x 480 but some of the features may appear distorted or may not be accessible on the
screen.
The resolution may be changed from the ‘Windows Control Panel’

• Click the ‘Start’ button

• Select ‘Settings’
• Select ‘Control Panel’
• Select ‘Display’

CASTLINE SYSTEMS Cablecalc Getting Started • 9

Before you begin

Help
If you require additional help whilst using Cablecalc for Windows, just press the F1 key at any
time to bring up either a help screen related to the area of the programme that you are using, or
the main Cablecalc for Windows help index. To return to the list below after reading each of the
items, just click on the Back button below the menus. Finally, to exit Help and go back to the
programme itself, press Alt & F4 or click on the File menu then choose Exit.

Starting Cablecalc

Starting Cablecalc
When you load Cablecalc for Windows, a title screen will be displayed while the main
programme is loading. The title screen will then clear to display the ‘Cable Calculator’ screen

Please note that there is a quick help system built in to the main screen. As the mouse cursor
passes over the various controls on the main screen a brief description of their uses is displayed

Starting a Calculation.
In the centre of the screen are the boxes, which allow you to enter the data needed to perform
calculations. The default values are already filled in but can be changed, either by over-writing
them or by changing the user default settings from the ‘Set Defaults’ menu.

You will notice that on the lower edge of the Cable Calculator there are Index Tabs. Each of
these tabs relates to a section of the current form and most of them will require the input of data.
To access the input screen associated with each Tab, click on the tab itself.

CASTLINE SYSTEMS Cablecalc Getting Started • 10

Boxes on the forms mainly require either text or a numeric value to be entered into them. If a box
has a button with an arrow pointing downward in it attached to it then pressing this button will
drop down a list of possible options that can be chosen. To select one of these options just click
once on it using the mouse.

NOTE: If there are more options in the list that can be displayed at any one time on the screen, a scroll bar will be shown at the
right-hand side of the list.

Small blank square boxes may be selected by clicking on them once with the mouse, and are
usually either/or or yes/no choices (e.g. the ‘Separate cable’ facility in the CPC details section).
When you click on this type of box the box will either becomes checked or will become blank.

Small round boxes surrounded by a frame denote various options, only one of which can be
selected at any time (e.g. the Type of Circuit buttons on the Voltage screen).

NOTE: In all cases context-sensitive help about any part of the data entry screens (and the rest of the programme) is available by
pressing the F1 key.

Saving Your Work (levels 2-3-4)

Once you have completed your calculations, the next operation is to print them. However, it is
advisable to save them first. This is achieved by choosing Open/Save File from the File Menu
with the mouse or by pressing Alt & F together, followed by O. See ‘Project Manager’

NOTE: You can also re-load this calculation should you need to come back to it at a later date by choosing the Open
Calculation File option from the File menu (Keyboard Shortcut: Press Alt & F followed by O).

Setting Your Printer

Before printing you may wish to check that the settings for your particular printer are correct.
Choosing Printer Set-up from the ‘File’ menu will display the standard Windows Printer Control
Box and allow you to change any required settings. However, in most cases this should not be
necessary. Refer to Printing Reports below as well as the Troubleshooting Guide later in this
manual. Please note that the Printout Defaults button allows you to customise the printout to your
exact requirements and can add/modify such items as Job Reference, Cable Reference etc. and
allow the setting of a top margin so that headed paper can be used.

Printing Reports
To print your Report, choose Print from the file menu or press the Print button at the bottom of
the Calculate screen. The current result will then be printed to the local printer. (Keyboard
Shortcut: Press Alt & F followed by P (For more details on printers and their configuration, refer
to the Microsoft Windows User Guide supplied with your computer). See also the
Troubleshooting Guide below. Please note the Printer Set-up may be accessed from any of the
following methods: -

a) From the file menu for configuring the printer & paper in use,
b) Keyboard Shortcut: Press Alt & F followed by R

CASTLINE SYSTEMS Cablecalc Getting Started • 11

c) Or the button on the Calculate Screen (used for setting various messages as well as the
style of type font for the printout).

Print Preview will allow you to see what your printout will look like before actually printing it
(see note below). It is available both by pressing the Print Preview button on the Calculate
screen as well as choosing Print Preview from the file menu (Keyboard Shortcut: Press Alt & F
followed by V). To exit from Print Preview press Alt & F4.

NOTE: Cablecalc for Windows will support colour printers if available and will print using the same colour(s) as displayed on
the screen. Also, what you see on the screen in the Print Preview is a representation of what appears on the printer, shown to the
correct scale. The printouts will, in nearly all cases, look clearer than this.

Correcting Calculation Errors

If you have an error in a calculation (i.e. a Fail) when you press the Calculate button you will see
that on the right hand side of the calculation box there are three coloured indicators which show
either “PASS” or “FAIL” dependant on the result of the calculation(s). Look at the values
associated with whichever indicator(s) that show “FAIL” and one or more of them should be
highlighted in RED. This will give you an idea of the cause of the problems with the calculation.
Figures 3a & 3b show some examples of this.

Hint Button
If a “FAIL” situation is flagged then the hint button will appear. Clicking on the hint button will
reveal some possible explanations and solutions for the calculation failure. To return to the
calculation screen click the hint button once more.

Viewing the sample file

We have included a small sample file called Castline. To view this file from the Cable calculator
screen click the command button ‘View Distribution Boards’ located at the bottom of the Cable
Calculator window. This will select the Project Manager, which will display distribution board
and circuit details.

To view the different types of schedules and reports that have been included in the sample file,
click on the command button ‘Schedules’. In the schedule screen you may select six types of
schedules and graphs from the menu schedule at the top of the screen. You may move between
different distribution boards by selecting from the bottom of the screen. Click ‘close’ to return to
the programme manager.

CASTLINE SYSTEMS Cablecalc Getting Started • 12

Setting up a Project File
To create a new project file for use with Cablecalc, select Set Up Project from the File menu
located on the top menu bar, giving your project a unique name using no more than eight
characters. (Note that when entering the name certain reserved characters, e.g.! ” £ $ % ^ & * ( )
_ /\ | < > # ~ @ ; : ? [ ] { } . , ‘ ¬ = cannot be used). You can also set up a new project file from
the New Project button on the Project Manager screen. For more information on setting up
project files see Projects: a beginners guide.

Project Default Values

Select ‘Set Defaults’ from the top menu bar

Or
From the Project Manager select ‘Details’ from the top menu bar

This area covers the supply characteristics for the project in question and will be the basis for all
of the calculations performed in this project.

The items covered are: -

Supply Voltage
Single phase e.g. 240
Three phase e.g. 415
Open Circuit e.g. 240

Volt Drop
Max permissible e.g. 4%

Supply impedance (Ze)

Ze (SPN) e.g. .25
Ze (TPN) e.g. .15

Ambient Temperature
Air e.g. 30
Ground e.g. 15
Soil Resistivity e.g. 1.2

CASTLINE SYSTEMS Cablecalc Getting Started • 13

 Short Circuit Current
Pscc (kA) e.g. 16

Power Factor
P.F. e.g. 1

Supply Details
Supply reference e.g. DB-1
Supply location e.g. Basement
Supply description e.g. Switch room at J.
Bloggs & Co.

Supplied from
Supplied from e.g. Source
Supplied from circuit e.g. Main incomer

If you want to revert to the original default values click on Use Default Values.

Create Distribution Boards

Create Distribution board

The Cablecalc ‘Project Manager’ must be displayed on the screen before this can be achieved.

To display the Cablecalc Project Manager if it is not already displayed, click ‘View Distribution
Boards’ at the bottom of the Cable Calculator screen (Supply Tab)

Or
From the drop down menus on the top bar select ‘File’ then ‘Open/Save File’

First select a Project by clicking on a project displayed in the project list

Select ‘Distribution Boards’ from the top menu bar and then select ‘New Distribution Board’
to display the new distribution board entry dialogue.

Enter the name of the distribution board using less than 20 characters. (Spaces are permitted).

CASTLINE SYSTEMS Cablecalc Getting Started • 14

Click OK to create the distribution board database file. The new distribution board should now
appear in the Distribution Board list.

Any number of Distribution boards may be added to a project file.

NOTE: Distribution boards cannot be re-named once they have been created therefore if you do wish to change the name of a
distribution board copy it naming it with the new name and then delete the original.

Formulae and Conversion

This section provides a handy ready reckoner set of information for converting between units as
well as providing a simple electrician’s calculator.

CASTLINE SYSTEMS Cablecalc Getting Started • 15

The Cable Calculator

Tab 1 - Supply

This area covers the supply characteristics for the circuit in question and most of the inputs can
be pre-set using the User defaults set up facility from the ’Set Defaults’ menu (Voltage, Ze,
PSCC, Pf and Volt drop). The main user inputs are for the selection of the type of circuit; the
Load input (Amperes) and the Length of the circuit (metres).

To calculate and save a cable

To calculate a cable, first select the appropriate distribution board from the list in the ‘project
manager’. This will then load the supply characteristics for that distribution board in to the cable
calculator, in the cable calculator window. Fill in the circuit number, phase and description
boxes and then proceed with your calculation as normal then click ‘save’ on completion.
Confirm details in the ‘save circuit’ screen and click ok.

Type of Circuit:
Radial circuit
This is the default option and is for a category 1 circuits
Radial circuits are conventional circuits feeding socket outlets,
lights etc.

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 17

 Ring circuit
Ring final circuits are circuits arranged in the form of a ring and
connected to a single point of supply.
This option is requires input for the distance (metres). The Load
input box will be disabled, as the load for the calculation of voltage
drop for the circuit is taken as 25% of the protective device rating.

NOTE: The Distance input for a ring circuit is to the half way point of the circuit or the distance to the furthest socket outlet, not
the total length of the cable from the protective device and then back again.

NOTE: Ring circuit. The Load input box will be disabled, as the load for the calculation of voltage drop for the circuit is taken
as 25% of the protective device rating.

Sub main
Circuits feeding distribution boards.
To calculate a sub main cable: From the ‘project manager’,
select the distribution board that the cable is coming from, then on
the cable calculator screen select ‘sub main’ and then select three
phase if relevant. A yellow grid should now be visible. In the left
column of the grid add the load in amperes, in the middle column
the distance in metres, then when you click to the right column a
drop down list will appear, select the relevant distribution board
that the cable is feeding. If your sub main cable is looping to more
than one distribution board then complete section two as
appropriate. Click ok and then go back to the cable calculator
screen and continue as normal. Another yellow grid will appear
displaying the result of the sub main(s), click ok to continue, and
then click on ‘save’.

Lighting circuit
This option is for category 1 circuits that are looped together e.g.
street lighting installations, three plate lighting installations and sub
mains. Each section of the circuit requires the load at that point and
the distance for that section of the circuit. Totals for the entire
circuit are displayed at the bottom of the input form and calculated
as the cursor moves to the next position.

Star Delta circuit

This option is for a category 1 star delta circuits and requires the
distance from the starter to the motor and the full load current for
the motor. The root three load is displayed in a separate text box
and is the load that will be carried by each of the six conductors in
the cable(s).

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 18

 Motor
Circuits feeding motors.

Diversity
Diversity may be applied to the circuits, anything between 5% and 100% in steps of 5%, with
100% representing the full load. For more information regarding Diversity see the I.E.E. On Site
Guide appendix 1 Maximum Demand and Diversity.

NOTE: the input is not accepted until the cursor is moved down and is clear of the last input.

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 19

Tab 2 - Cables

This area covers the cables available and their are no user defaults available. Cable parameters
should be selected in the following order

Conductor

Type

Insulation

Cable Type

Installation method

Cores

Size/Calculate

Parallel cables

Selecting Calculate will calculate the minimum size of cable suitable for the circuit, selecting an
actual cable size from the drop down list will evaluate the circuit based on the size of cable
selected.

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 20

Tab 3 - Protection

Overload / short circuit protection

Select either overload and short circuit protection or Short circuit protection only.

See regs 473-01 and appendix 4 sections 4 & 5 for details

Type of circuit
Select the type of circuit from the options in this section (Fixed equipment / Socket outlets), the
maximum permissible disconnection time will be displayed for the option selected.
Maximum disconnection time permitted.
Fixed equipment 5.0 secs.
Socket Outlets 0.4 secs.
Socket outlets special locations 0.2 secs.
See On Site Guide Section 3.5 - Disconnection Times.

Select Protective Device

This area covers the Protective devices available; there are no user defaults available. Parameters
may be selected in any order. The system default protective device type is the BS 88 Cartridge
fuse, this was chosen as the system default because it contains the greatest range of current
ratings (2-800 A). Cablecalc for Windows will automatically select the lowest protective device
size greater or equal to the load for the circuit. To increase or decrease the protective device
rating click on the arrows below the Rating (Amperes) display window (left arrow to decrease,
right arrow to increase). If the protective device rating selected is lower than the load for the
circuit then the colour of the display will change from black to red.

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 21

The Max Zs (ohms) window displayed is the impedance value for the protective device selected.

NOTE: The total impedance for the circuit (including the external impedance) must not
exceed this value or else a fail situation will arise.

The Multiplier display shows the figure that is multiplied to the protective device rating to
provide the tripping current, and is used in the following formulae to obtain the protective device
impedance (Zs): -
Open circuit volts / Protective device rating x multiplier

Multipliers for miniature circuit breakers used in Cablecalc for Windows are as follows: -
Type 1 4
Type 2 7
Type 3 10
Type 4 50
Type B 5
Type C 10
Type D 50

Example: type 2 mcb - 10ampere - 240V open circuit voltage

240 / 10 x 7 = 3.428 ohms

Magnetic Setting window (ACBs and MCCBs only) use the control below this window to adjust
the setting of the circuit breaker (left arrow to decrease, right arrow to increase).

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 22

Tab 4 – Derating

This area covers the derating factors that will affect some of the characteristics for the cable
selected, these include: -
the effective current rating,
the operating temperature,
the millivolt drop per metre.

Temperature (Ca)
From the drop down list select the ambient air temperature applicable for the circuit, the
correction factor for the selected temperature is displayed in the adjacent text box. User pre-set
available

NOTE: The Temperature for direct buried cables and cables in ducts is based on a ground temperature of 15°C, the temperature
for all other cables is based on an ambient temperature of 30°C.

Grouping (Cg)
From the drop down list, select the number of circuits or multicore cables grouped with this
circuit, the correction factor for the selected number of cables is displayed in the adjacent text
box.

NOTE: If due to known operating conditions, a cable is expected to carry not more than 30% of its grouped current rating, it
may be ignored for the purpose of obtaining the rating for the rest of the group. See regs appendix 4 tables 4B1, 4B2 & 4B3 for
details.

Thermal insulation (Ci)

From the drop down list, select the length of thermal insulation as appropriate, the correction
factor for the selected length of thermal insulation selected is displayed in the adjacent text box.

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 23

NOTE: See regulation 523-04 & table 52A for details.

Fuse (Cf)
The correction factor for the protective device selected will be displayed. If a rewireable fuse to
BS 3036 has been selected then a factor of 0.725 will be displayed; all other protective devices
will display a factor of 1.

Correction Factor (Ct)

The total correction factor for the circuit will appear in this text box; this factor will be applied to
the tabulated current rating for the cable.

Calculation method
The Use worst case only option will apply the lowest of all the correction factors.

NOTE: This is not the recommended method of calculating the correction factor and should be used with caution.

The Calculate using all factors option (standard method) will apply the sum of all the correction
factors to the tabulated current rating for the cable.

NOTE: See appendix 4 for details.

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 24

Tab 5 - CPC Details
This area covers the circuit protective device (cpc) options and contains three tabulated
sections

Select CPC
Various options are available for the selection of the cpc for the cable (you may select more than
one option) and include: -

Sheath or Armour

Internal core

Conduit
This section displays a list containing light duty and heavy-duty
conduit sizes from 16mm up to 32mm. If Steel conduit is selected
then the conduit resistance may be included in the earth
calculation.

Trunking
This section displays a list containing trunking sizes from 50mm x
50mm up to 300mm x 150mm If Steel trunking is selected then the
resistance of the trunking may be included in the earth calculation.

Separate cable
This option if selected displays four methods for adding a separate
cpc: -
The default is to calculate the size in accordance with Table 54G
Use same size as cable
This will add a separate cpc to the calculation that is the same size
as the cable under evaluation.

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 25

 Calculate size
This will calculate the size of a separate cpc up to a maximum size
of 1000mm²

Select size
This option will display a drop down list box containing cpc sizes
from 1.0mm² to 1000mm² select the desired size from the list.

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 26

Tab 6 - Calculate

This area displays a summary of the calculation/evaluation and is divided into three logical
sections providing a pass/fail flag for each section. For more information see Calculation Related
Problems and Correcting Calculation Errors elsewhere in this manual. At the bottom of this
section are buttons to Save, Printout Defaults, Print Preview and Print, these items are
described elsewhere in this manual.

Cable Size
This section displays the cable size, the number of cables in
parallel, the length of the circuit, a description of the cable, the
voltage and phase details and the tabulated and effective ratings of
the cable. To increase/decrease the cable size or add/subtract cables
in parallel, click on the arrows below the relevant items.

Volt Drop
The calculated volt drop and the permitted volt drop for the circuit
is displayed both in volts and as a percentage of the line voltage.
The millivolts per Ampere per metre (mV/A/mtr), and the
corrected mV/A/mtr are also displayed. The Tabulated values of
(mV/A/mtr) are the values taken from the tables in the IEE
regulations, or alternatively from cable manufacturers data sheets.
The corrected values are the tabulated mV/A/mtr values with
correction for operating temperature applied. The volt drop
calculation is based on the corrected value.

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 27

 Impedance
This section displays the following information: -

R1

R2

R1+R2

Zs

PSCC

Withstand time

cpc size

Zsc (origin)

Zsc (circuit)

Earth Fault Current

Calculation related problems

Calculation problems are highlighted within the calculate screen by FAIL flags and the relevant
item(s) displayed with a red background. These will be in the following areas:

1.) Cable Size

A fail situation here could be caused by: -

Problem Effective current rating highlighted. The load exceeds the effective current
rating of the cable
Suggestion Increase the cable size.
Suggestion Add an additional cable in parallel.
Suggestion Check that the derating factors are correct especially the factor for grouping as
in some circumstances this may be ignored (see regulations appendix 4 notes to
table 4B2).

Problem Load highlighted. The effective current rating of the cable is less than the rating
of the protective device.
Suggestion Increase the protective device size (the protective device rating is displayed red if
the value is too low).

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 28

 2.) Volt Drop
A fail situation here could be caused by: -

Problem Volt Drop highlighted The calculated volt drop exceeds the maximum
permitted volt drop.
Suggestion Increase the cable size
Suggestion Add an additional cable in parallel.

3.) Impedance
A fail situation here could be caused by: -

Problem Zs highlighted. The cable/cpc Zs value is greater than the protective

device Zs value
Suggestion Increase the cable size
Suggestion decrease the protective device size
Suggestion Increase the cpc size
Suggestion Add a separate cpc
Suggestion Check that the supply impedance(Ze) is correct, (the impedance of the cable/cpc is
added to the Ze, this total must be less than the Zs value of the protective device).

Problem R2 highlighted. There is no cpc present.

Suggestion Add a cpc

The Hint button will offer some suggestions for ‘Fail’ situations.

CASTLINE SYSTEMS Cablecalc The Cable Calculator • 29

The Project Manager

The Project Manager

The Project manager is the heart of the Cablecalc programme. It is from the Project manager that
projects can be created and distribution boards added and circuits edited or recalculated.

Projects may be selected using the Project dialogue box together with the Drive and Directory
lists located at the top of the ‘Project Manager’.

Circuit sort order may be displayed in three different ways by selecting either ‘Numeric’ ‘Phase’
or ‘None’ from the ‘Sort order’ section.

The circuit grid details may be changed using the ‘Overview’ ‘Device Details’ ‘Cable Details’
‘Cost Analysis’ buttons (Level 4 only).

The ‘Summary’ section provides totals for either the design Amperes or the Diversified Amperes
(The circuit design loads multiplied by the diversity factors).

The Voltage Impedance and Fault current for the board is displayed at the bottom left of the
‘Project Manager’.

CASTLINE SYSTEMS Cablecalc The Project Manager • 31

 Buttons
Edit Circuit
Select a circuit from the grid by clicking on any grid cell and
then click the ‘Edit Circuit’ button to reload the calculation.

New Circuit
Click the ‘New Circuit’ button to reload the ‘Cable
Calculator’.

Delete Circuit
Select a circuit from the grid by clicking on any grid cell and
then click the ‘Delete Circuit’ button to delete a circuit.

Copy Circuit
Select a circuit from the grid by clicking on any grid cell and
then click the ‘Copy Circuit’ button to copy the circuit.

Schedules
This will load the ‘Report’ section of Cablecalc

Calculate ***
Click this button to recalculate all of the circuits in the
distribution board.

Calculate All
Click this button to recalculate all of the circuits in the all of
the distribution boards in the project.

Exit Manager
Return to the ‘Cable Calculator’.

Overview
Click this button display the default calculation results for the
currently loaded distribution board.

Cost Analysis
Click this button display the costs currently loaded
distribution board. (Level 4 only).

CASTLINE SYSTEMS Cablecalc The Project Manager • 32

 Device Details
Click this button display the protective device details for the
currently loaded distribution board.

Cable Details
Click this button display the cable details for the currently loaded
distribution board.

Menus
Close
This will return to the ‘Cable Calculator’

Project
New Project Create a new project
Copy Project Create a new project
Delete Project Create a new project

Distribution Boards
New Distribution Board Add a new Distribution board
Copy Distribution Board Copy an existing Distribution
board
Delete Distribution Board Delete an existing Distribution
board

CAD
Display the Drawing Utility (Level 4 only).

Calculate
Calculate This
Distribution Board Select this menu to recalculate
all of the circuits in the
distribution board.
Calculate All Select this menu to recalculate
all of the circuits in the entire
project.

CASTLINE SYSTEMS Cablecalc The Project Manager • 33

 Details
Click this button display the cable details for the currently
loaded distribution board.

Export
Click this button display the cable details for the currently
loaded distribution board.

Projects: A beginners guide.

Project File
e.g. FACTORY1

Distribution Board Distribution Board Distribution Board

e.g. DB1 - Lighting e.g. DB2 - Power e.g. DB3 - Heating

Circuits Circuits Circuits

As you can see from the above diagram, a project file contains all the elements of the job. Please
note that calculations can not be saved until a suitable distribution board file has been set up and
loaded.

A project file is the container file for any number of distribution board files

A project file name must not consist of any reserved characters or use any spaces (see Setting up
a Project).

A Distribution Board file is the container file for saving calculation results (circuits).

A Distribution Board file name may be more than eight characters in length and may contain
spaces.

A circuit file may only be saved to a Distribution Board file.

A circuit file must contain a circuit reference number e.g. 5 and a valid phase reference colour
e.g. RYB (you will be prompted for this information when click on the “Save Circuit” button in
the “Project Manager” form). Valid phase references are: - R Y B and RYB.

CASTLINE SYSTEMS Cablecalc The Project Manager • 34

 1) Create Project file

A project file may be created either from the Cablecalc Project manager or from the New Project
Dialog box.

a) To create a Project file from the New Project Dialogue box, from the File Menu select Set
Up Project.
b) To create a Project File from the Cablecalc Project manager, from the File menu select
Open/Save File to display the Cablecalc Project manager. Click on the New Project
button to display the New Project Dialog box.
In the text box marked File Name enter the name of the new project (using no more than 8
characters) e.g. Factory1 and then click OK.

2) Create Distribution board within the project file.

The Cablecalc Project manager must be displayed on the screen before this can be achieved. To
display the Cablecalc project manager from the File menu select Open/Save File.

First select a Project by clicking on a project displayed in the project list.

Click on the button marked New Dis’Board to display the new distribution board entry dialogue.
Enter the name of the distribution board using less than twenty characters. (Spaces are
permitted).

CASTLINE SYSTEMS Cablecalc The Project Manager • 35

Click OK to create the distribution board database file. The new distribution board should now
appear in the Distribution Board list.

Any number of Distribution boards may be added to a project file.

3) Save a circuit within the Distribution board file.

If you have just performed a calculation then you may save the calculation results by clicking on
the Save Circuit button.

You will be asked for the following details:-

Circuit Number e.g. 6

Phase e.g. R
Description e.g. Office 1 Lighting
Installation method e.g. PVC in conduit

Click OK to save the data.

If you want to save data for a circuit from scratch without performing a calculation (Inspection
and testing) then this can be done by clicking on the Edit circuit button.

Before the main circuit database entry screen appears a message with a reminder to click the add
circuit button before adding a new circuit will be displayed. What this means is that before
filling in all the data for a new circuit you must first establish the new circuit in the database, if
this is not done then the new data will not be saved. This needs to be done for each NEW circuit
that you add. Once the circuit has been established you will not need to use the Add Circuit
button again for that same circuit.

Any number of circuits may be added to a distribution board file.

Click on the ‘load circuit’ button to continue.

To calculate and save a cable

To calculate a cable
First select the appropriate distribution board from the list in the ‘project manager’. This will
then load the supply characteristics for that distribution board in to the cable calculator, in the
cable calculator window. Fill in the circuit number, phase and description boxes and then
proceed with your calculation as normal then click ‘save’ on completion. Confirm details in the
‘save circuit’ screen and click ok.

CASTLINE SYSTEMS Cablecalc The Project Manager • 36

 To calculate a sub main cable.
From the ‘Project Manager’, select the distribution board that the cable is coming from, then on
the cable calculator screen select ‘sub main’ and then select three phase if relevant. A yellow
grid should now be visible. In the left column of the grid add the load in amperes, in the middle
column the distance in metres, then when you click to the right column a drop down list will
appear, select the relevant distribution board that the cable is feeding. If your sub main cable is
looping to more than one distribution board then complete section two as appropriate. Click ok
and then go back to the cable calculator screen and continue as normal. Another yellow grid will
appear displaying the result of the sub main(s), click ok to continue, and then click on ‘save’.

CASTLINE SYSTEMS Cablecalc The Project Manager • 37

Utilities

The Time Curve Utility.

The Cablecalc “Plus” for Windows Time/Current curve utility has been developed to produce
graphs for displaying protective device time/current characteristics for a large number of
commonly used fuses and circuit breakers.

The menus
File
Save to File
Enables the displayed graph to be saved as a bitmap image (*.bmp). Select this option if you
intend to add the graph to a document created in any other Windows programme. Once
created and then exported to a Windows desktop publishing or Word-processing programme
the bitmap images may be sized as required.

Print Graph
This will send a copy of the displayed graph to the local printer. If your printer is a colour
printer then the print will be in colour. Note: Beware of using dark background colours when
using ink jet printers as this will tend to make the graph lines merge into the background
resulting in a messy print out.

CASTLINE SYSTEMS Cablecalc Utilities • 39

Exit
Exits Time Curve and returns to the main Cablecalc for Windows screen.

Set Up
Colours
Select the screen colours for: -

Graph background
Graph border
Graph curve lines
Graph log-log lines
Graph text
Graph time indication

Three buttons are displayed at the bottom of this form and are as follows: -
OK
This will save the colours that you have selected
Cancel
This will quit the Colour set up option without saving the changes
Set default
This will reset the screen colours to the default colour scheme.

Disconnection Time
This will enable the user to produce a graph displaying an accurate assessment of
disconnection time or operating time for a protective device.
Disconnection time or operating time is the time taken from the commencement of a current
large enough to cause the fuse elements to melt (or in the case of a circuit breaker, the
mechanical contacts to separate), through to the breaking of the circuit. The protective device
must be capable of breaking the circuit before any overload current (If) can cause a rise in
temperature which may damage the current carrying conductor or any of its associated
equipment.

1) Select Disconnection Time from the menu to reveal the data

input screen.
2) Select the type of protective device from the Select protective
device list.
3) Select the Rating of the protective device by clicking on the up
and down arrows.
4) Input the Fault current in Amperes, (this will automatically
display the Fault current from the last calculation performed in
Cablecalc for Windows)
5) Select continue to calculate and view the results on screen.

CASTLINE SYSTEMS Cablecalc Utilities • 40

Discrimination
Discrimination of a protective device is the requirement to co-ordinate overload and short
circuit protection by assessing the characteristics of the devices used so that energy let through
by one device does not exceed that of any upstream protective device or devices. The total I²t
let through energy of the smaller device should not exceed or be too close to the prearcing
value of the next larger device. If it is larger then the larger device could operate before the
smaller device.
To illustrate this situation Cablecalc “Plus” Time / Curve will allow any number of protective
devices to be displayed at any one time. As a general rule, if the curve of a device touches or
overlaps that of any other device then discrimination is not achieved and the larger device
could be the first to fail.

1) Select Discrimination, and then select Add Protective

Device from the menu to reveal the data input screen.
2) Select the type of protective device from the Select
protective device list.
3) Select the Rating of the protective device by clicking on the
up and down arrows.
4) Select continue to display the protective device
characteristics on screen.
5) Repeat as required.

Fault Lines
A conductor fault line is a line plotted against a graph showing the maximum fault a current
carrying conductor can withstand for a given disconnection time. When a conductor line is
superimposed against a protective device time / curve, where the line crosses the curve
indicates the maximum disconnection time for that particular cable and insulation
combination. As a general rule of thumb, if the fault line is to the right of the curve then the
situation is acceptable.

1) Select Fault Lines from the menu to reveal the data input
screen.
2) Select the type of protective device from the Select
protective device list.
3) Select the Rating of the protective device by clicking on the
up and down arrows.
4) Select the type of Conductor from the available Conductor
options
5) Select the type of Insulation from the available Insulation
options
6) Select the Size of cable from the Cable Size list.

If you wish to display disconnection time as well as a conductor fault line, then Input the fault
current in Amperes. (This will automatically display the Fault current from the last calculation
performed in Cablecalc for Windows). If this input is left blank then no disconnection time
characteristics will be displayed.
Select continue to calculate and view the results on screen.

CASTLINE SYSTEMS Cablecalc Utilities • 41

Clear
Use this menu option to clear all items from the graph.

The Conduit Utility

Cablecalc “Plus” for Windows Conduit size utility may be used to determine capacities of
conduits using the method described in Appendix A “Cables capacities of conduit & trunking”
of the guidance notes for the 16th Edition Wiring Regulations (Number 1 - Selection &
Erection). The units used for the calculation are terms, as used by the British Electrical
Systems Association (BESA) and are based upon diameter.

The menus
File
Save
Saves the current calculation as a *.con file.
Open
Loads and opens an existing file.
New
Creates a new file.
Print
Prints the current file data.
About
Displays an overview of Conduit Size

CASTLINE SYSTEMS Cablecalc Utilities • 42

Exit
Exits Conduit and returns to the main Cablecalc for Windows screen.

Help
Getting Help
Displays a message on how to obtain help
Keys
Describes the short-cut keys
The following inputs may be performed in any order: -

Select the length of the conduit run from length of run list
Select the number of bends in the conduit run from the Number of
bends list.
Select the size of conduit from the Conduit size list.

Input the number of cables for each relevant cable size in the data entry grid, the terms per
cable and the total terms are automatically displayed in the adjacent grid cells.
Important To accept the quantity into the calculation you must either press the enter key or
move to another grid cell using either the up or the down arrow keys
The totals are displayed beneath the grid for the number of cables (regardless of size and the
number of terms).

Displays
The % used
Is the percentage of the conduit that is used, if this figure exceeds the predetermined criteria a
FAIL message will appear.
The % spare
Is the percentage of the conduit that is not used, if this figure exceeds the predetermined
criteria a FAIL message will appear.
Default % setting
The default setting is the percentage relative to the recommended maximum capacity
permitted by the IEE regulations (This is regarded as 100%). The provision to change this
figure is useful for providing space for future expansion or additions to the installation. i.e. a
specification may require that all conduits have a free capacity of 25% for future expansion, in
which case the default % would be set by the user to 75%. This will ensure that all conduits
are filled to within the specified limits.
The buttons at the bottom of the conduit screen duplicate the menu options listed previously

CASTLINE SYSTEMS Cablecalc Utilities • 43

The Trunking Utility
Cablecalc “Plus” for Windows Trunking size utility may be used to determine capacities of
trunking using the method described in Appendix A “Cables capacities of conduit & trunking”
of the guidance notes for the 16th Edition Wiring Regulations (Number 1 - Selection &
Erection). The units used for the calculation are terms, as used by the British Electrical
Systems Association (BESA) and are based upon diameter.

The menus
File
Save
Saves the current calculation as a *.trk file.
Open
Loads and opens an existing file.
New
Creates a new file.
Print
Prints the current file data.
About
Displays an overview of Trunking Size
Exit
Exits Trunking and returns to the main Cablecalc for Windows screen.
Help
To obtain on line help press the F1 function key.

CASTLINE SYSTEMS Cablecalc Utilities • 44

 The following inputs may be performed in any order:-
Select the size of trunking from the Trunking size list.
Input the number of cables for each relevant cable size in the data entry grid.
The total number of cables is automatically displayed regardless of size in the total box.

Displays
The % used
Is the percentage of the trunking that is used, if this figure exceeds the predetermined criteria a
FAIL message will appear.
The % spare
Is the percentage of the trunking that is not used, if this figure exceeds the predetermined
criteria a FAIL message will appear.
Default % setting
The default setting is the percentage relative to the recommended maximum capacity
permitted by the IEE regulations (This is regarded as 100%). The provision to change this
figure is useful for providing space for future expansion or additions to the installation. i.e. a
specification may require that all trunking runs have a free capacity of 25% for future
expansion, in which case the default % would be set by the user to 75%. This will ensure that
all trunking runs are filled to within the specified limits.
The buttons at the bottom of the trunking screen duplicate the menu options listed previously.

The Diversity Utility

Allowances for Diversity are determined using the method described in Appendix J “Maximum
Demand and Diversity” of the guidance notes for the 16th Edition Wiring Regulations (Number 1
- Selection & Erection).

CASTLINE SYSTEMS Cablecalc Utilities • 45

 The menus
File
Save
Saves the current calculation as a *.dvy file.
Open
Loads and opens an existing file.
New
Creates a new file.
Print
Prints the current file data.
Exit
Exits Diversity and returns to the main Cablecalc for Windows screen.
About
Displays an overview of Diversity.
Help
To obtain on line help press the F1 function key.

To calculate diversity first select the type of premises from the premises options: -
Individual Household installations
Small shop, stores, offices, business premises
Small hotels, boarding, guest houses etc.

The following inputs may be performed in any order: -

Lighting
Heating

CASTLINE SYSTEMS Cablecalc Utilities • 46

 Cooking
Motors
Water heaters (instantaneous)
Water heaters (thermostat)
Floor warming
Storage heaters
Final circuits
Socket outlets

Input the Load in Amperes for the relevant items, the full load current and the diversified current
are automatically displayed in the totals boxes.

CASTLINE SYSTEMS Cablecalc Utilities • 47

Trouble Shooting

Version
To find the version number of the programme on your computer select ‘About’ from the ‘Help’
drop down menu.

Where to look for answers

If your problem is of an electrical nature, such as a calculation that seems to be giving strange
values or failing unnecessarily, examine the Calculation Related Problems below. Otherwise, if
the computer just wont print, or you have other problems of this nature, refer to Computer
Related Problems. If you are having problems in using the programme we recommend that you
use the Cablecalc for Windows Getting Started featured earlier.

Computer Related Problems

The following covers possible problems of a computer nature that may be encountered when
using Cablecalc for Windows, together with suggested solutions.

1. Some Laser printers may have difficulty printing this on-line manual often resulting in a
memory error as well as it printing in three or more sections. If this happens to you, you
may need to change the settings on the printer in Windows. Try decreasing the setting
marked resolution to 150 dpi (see your Windows manual for details on how to do this).

NOTE: The manual may take up to ten minutes to print, including a large pause before the printer starts working. This is quite
normal, and is not a problem with the software or your system. However, you should ensure that you have at least 4 Megabytes of
free space on your hard disk to accommodate the temporary print file before starting to print.

2. When selecting fonts for the calculation printout always run a Print Preview before
deciding on a font to use because some fonts produce unexpected effects (and can be
unreadable, if a font such as Symbol or Wingdings is selected!). If in doubt, stick to the
standard two readable fonts that are supplied with Windows, Times New Roman and Arial.
3. If the software prints a demonstration Watermark across all the printouts this normally
means that the software is either a demonstration version of the programme or that it is the
full version but has been incorrectly installed. If this happens (and you are NOT running a
demonstration copy) check at the top of the screen to see if you are running the correct

CASTLINE SYSTEMS Cablecalc Trouble Shooting • 49

 level. If the level is displayed as ‘Level 0’ then the software has been incorrectly installed.
In the event of this happening to you, in the first case try re-installing the software using the
correct method. If this still does not cure the problem, contact Castline Systems.

CASTLINE SYSTEMS Cablecalc Trouble Shooting • 50

Operation problems

Error codes

5 Illegal function call

55 File already open
6 Overflow
57 Device I/O error
7 Out of memory
58 File already exists
9 Subscript out of range
61 Disk full
11 Division by zero
67 Too many files
13 Type mismatch
68 Device unavailable
28 Out of stack space
70 Permission denied
48 Error in loading DLL
71 Disk not ready
51 Internal error
74 Cannot rename with different
drive
52 Bad file name or number

75 Path / File access error

53 File not found

76 Path not found

54 Bad file mode

CASTLINE SYSTEMS Cablecalc Trouble Shooting • 51

 Most of the above errors are self evident but care must be taken to input the correct data,
omitting data may cause the programme to error.

Error numbers 5 to 51 are mathematical / data errors

Error numbers 52 to 76 are disk / file / path errors
Printer Errors should be trapped by the operating system

CASTLINE SYSTEMS Cablecalc Trouble Shooting • 52

Glossary of Terms

NICEIC
National
Inspection
Council for
Electrical
Installation
Contracting

P.F.
Power Factor

Pscc
Prospective
Short Circuit
Current

Ze
Phase earth
loop
impedance
from the
source of
energy to the
end of a final
circuit

CASTLINE SYSTEMS Cablecalc Glossary of Terms • 53

CASTLINE SYSTEMS Cablecalc Glossary of Terms • 54
 Index Tabs ............................................... 10
Index Installation ................................................. 9
L
Laser Printers ........................................... 49
Lighting Circuit.................................... 8, 18
Load........................................17, 18, 28, 47
A
M
Ambient Temperature .............................. 13
Menus ...................................................... 33
B Motor....................................................... 19
Bitmap Image........................................... 39 Multiplier ................................................. 22
Buttons..................................................... 32
O
C Operation problems.................................. 51
Cable Calculator ............... 10, 12, 14, 32, 33 Overload / short circuit protection ............ 21
Cable Size ................................................ 27
P
Cables ...................................................... 20
Calculate and Save a Cable ................ 17, 36 Plus............................................................ 7
Calculation Errors .............................. 12, 27 Power Factor...................................... 14, 53
Calculation method .................................. 24 Print Graph .............................................. 39
Calculation related problems .................... 28 Print Preview ............................... 12, 27, 49
Computer Related Problems ..................... 49 Printing Reports ....................................... 11
Correction Factor ..................................... 24 Professional................................................ 8
Create Distribution board ......................... 14 Project Default Values.............................. 13
Create Project file..................................... 35 Project Manager .... 11, 12, 13, 14, 31, 34, 37
Projects A Beginners Guide ..................... 34
D
R
Discrimination ......................................... 41
Distribution Board ....................7, 33, 35, 36 Radial Circuit ........................................... 17
Diversity .................................................. 19 Resolution............................................ 9, 49
Diversity Utility ....................................... 45 Ring Circuit ............................................. 18
E S
Elite ........................................................... 8 Sample File .............................................. 12
Error codes............................................... 51 Save a circuit within the Distribution board
file. ....................................................... 36
F Saving Your Work ................................... 11
Fail..........................................12, 28, 43, 45 screen resolution ........................................ 9
Fault Lines ............................................... 41 Select CPC............................................... 25
Formulae and Conversion......................... 15 Select Protective Device........................... 21
Set Defaults........................................ 10, 17
G
Setting up a Project File ........................... 13
Grouping (Cg).......................................... 23 Setting Your Printer ................................. 11
H Short Circuit Current.......................... 14, 53
Star Delta circuit ...................................... 18
Help ......................................................... 10 Starting a Calculation............................... 10
Hint Button .............................................. 12 Starting Cablecalc .................................... 10
I Sub main.................................................. 18
Supplied from .......................................... 14
Impedance................................................ 28 Supply Details.......................................... 14

CASTLINE SYSTEMS Cablecalc Glossary of Terms • 55

Supply Impedance.................................... 13
Supply Voltage ........................................ 13
T
Tab 1 - Supply ......................................... 17
Tab 2 - Cables.......................................... 20
Tab 3 - Protection .................................... 21
Tab 4 – Derating ...................................... 23
Tab 5 - CPC Details ................................. 25
Tab 6 - Calculate...................................... 27
Temperature (Ca)..................................... 23
The Cable Calculator ............................... 17
The Conduit Utility .................................. 42
The Project Manager................................ 31
The Time Curve Utility. ........................... 39
Thermal insulation (Ci) ............................ 23
To Calculate a Cable................................ 36
To Calculate a Sub Main Cable.......... 18, 37
Trouble Shooting ..................................... 49
Trunking Utility ....................................... 44
Type of Circuit................................... 17, 21
U
User Ddefaults ......................................... 17
Utilities.................................................... 39
V
Volt Drop .....................................13, 27, 29

CASTLINE SYSTEMS Cablecalc Glossary of Terms • 56