SUMMARY

POWER CABLES DESIGNS.............................................................................127

CONSTRUCTIONAL ELEMENTS OF POWER CABLES .........................129

CONDUCTORS CHARACTERISTICS ...........................................................131

INSULATION AND SHEATHING MATERIAL CHARACTERISTICS ...133

DRUMS CHARACTERISTICS ..........................................................................134

ELECTRICAL CABLES CHARACTERISTICS ...................................................135

GUIDE FOR SELECTION OF LOW VOLTGE CABLE ...............................137

 POWER CA BLES DESIGNS

Transmission cables practices are - Bare hard drawn stranded all *LSZH : Low Smoke Zero Halogen
fairly similar in many countries. For aluminium conductors (AAC). material
wiring type cables, many individual - Bare hard drawn stranded all
countries have preferences for aliminium alloy conductors (AAAC). LOW VOLTAGE OUTDOOR CABLES
particular designs or materials, but - Aluminium conductors steel Outdoor low voltage cables are
the difference is not fundamental. reinforced (ACSR). usually exposed to serious weather
The present catalog covers Aerial lines with insulated conductors influences, high mechanical stresses and
essentially low and medium - Weather proof service drop dangerous chemical attacks,
voltage cables up to 33 KV, copper cables 0,6/1KV , XLPE For these reasons, they are
manufactured according to insulated for over head power lines. characterized by increased thickness in
European and international - Weather proof service drop the insulation and in the protecting outer
specifications which are largely aluminium cables 0,6/1KV, XLPE sheath, as well as by special insulating
used in Europe and the majority of insulated for over head power lines. and sheathing in case of presence of
countries throughout the world . various dangerous chemicals in the
LOW VOLTAGE INDOOR CABLES ground, where the cables are to be
Power cables are distinguished in Indoor cables are destined for placed and whenever fire retardant
the following categories permanent (fixed) as well as for qualities are required in case of fire.
Overhead (Aerial) lines with bare movable installations inside covered When the cables are destined to be
conductors. areas, protected from direct rain falls, buried direct in ground, they are
Overhead (Aerial) lines with as well as from moisture presence. normally protected with steel tape,
insulated conductors. These cables are mainly composed of when limited tensile stress are present
Low voltage (LV) power cables solid or stranded or flexible copper during installation and only protection
for indoor installations. conductors, insulated with PVC against mechanical damages are
Low voltage (LV) power cables Wherever fire retardant qualities, requested.
for outdoor installations. reduced fumes, toxic and corrosive When the contrary, cables subjected
Low voltage (LV) special cables gases emission in case of fire are to higher tensile stress during their
destined to special uses. required, they should be insulated installation, due to high pulling forces or
Medium Voltage (MV) power and sheathed with LSZH* material. to the presence of not stable or sandy
cables. The most common types of indoor ground, as well as when exposed to
cables, used in internal fixed or exaggerate mechanical pressures, they
OVERHEAD POWER LINES movable installations are the must be provided with an armour of
Overhead lines are generally following: round or flat galvanized steel wires
divided from the point of view of - Single core cables with solid or The most common types of outdoor
their use, into 3 main categories , as stranded copper conductors, PVC cables, used in external permanent
follows : insulated. (fixed) installations, are the following:
- Overhead lines for low voltage - Single core cables with flexible - Single core and multicore cables
power distribution in rural areas, as copper conductors, PVC insulated. with solid or stranded copper or
well as in small villages - Multicore cables , with solid or aluminium conductors , PVC insulated
- Overhead lines used for stranded copper conductors, PVC and PVC sheathed.
medium voltage power insulated and PVC sheathed. - Multicore cables with solid or
transportation and distribution - Multicore cables, with flexible stranded copper or aluminium
- Overhead lines used for High copper conductors, PVC insulated conductors , PVC or XLPE insulated and
Voltage power transportation from and PVC sheathed. PVC sheathed.
generating stations to big power - Flt-twin or flat-three core cables, - Multicore cables with solid or
consumers with solid or stranded copper stranded copper conductors, PVC or
Aerial lines with bare conductors conductors, PC insulated and PVC XLPE insulated, steel tape or steel wires
- Bare soft drawn stranded sheathed. armoured and PVC sheathed.
copper conductors - Multicore cables , with solid or - Multicore cables with stranded
- Bare hard drawn stranded stranded copper conductors, LSZH* sector-shape copper or aluminium
copper conductors. insulated and LSZH* sheathed. conductors, PVC or XLPE insulated and

T U N I S I E 127 C Â B L E S
PVC sheathed. *HFFR : Halogen free flame following classes:
- Multicore cables with stranded retardant Class1 : Solid copper and aluminum
sector-shape copper or aluminium conductors
conductors, PVC or XLPE insulated, SPECIAL CABLES
Steel tape or steel wire armoured There is a very big variety of special Class 2 : Stranded copper and
and PVC sheathed. cables, appropriately manufactured aluminium conductors
- Multicore cables with solid or to make front to special requests like Class 5 : Stranded flexible copper
stranded copper conductors, PVC welding, airport lighting and ship conductors
or XLPE insulated, steel tape or steel wiring.
Class 6 : Stranded super flexible
wires armoured and PVC sheathed
- Multicore cables with solid or COXIAL AND TV ANTENNA copper conductors
stranded copper or aluminium SATELLITE CABLE
conductors, LSZH* insulated and Coaxial cables are commonly used INSULATION AND SHEATHING
LSZH* sheathed. for central installations in civil MATERIAL
*LSZH : Low Smoke Zero Halogen buildings, where a central antenna
material The insulating materials used in power
positioned on the highest point of the
building, is connected to all cables are essentially the following :
CONTROL CABLES FOR apartments TV receivers, through Thermoplastic materials (PVC and PE)
INDOOR AND OUTDOOR vertical distributing lines of coaxial Thermosetting materials (XLPE)
INSTALLATIONS cables, which feeds the TV plugs. Electrometric materials as :
Control cables are composed of
Natural rubber
soft drawn solid, stranded, flexible MEDIUM VOLTAGE CABLES
and super flexible copper Medium voltage (MV) cables are Synthetic rubber
conductors, PVC or XLPE insulated, normally used for transporting electric Special insulating and sheathing
assembled into a cable core, filled power at medium distances and for materials (EPR or EPDM, EVA, PCP, CSPE
with plastic or rubber materials, safety reasons; they are installed and CPE).
eventually screened with copper underground directly to the soil or
tapes or wires, double steel tape or into ducts or in air over steel racks
steel wire armoured and finally PVC anchored against the wall. CABLE ARMOUR
sheathed. The MV cables covered by IEC 60502 All underground cables especially those
Wherever fire retardant qualities, are ranging from 3KV up to 33 KV. laid direct to ground are armoured with
reduced fumes, toxic and 1- CONDUCTORS (usually copper, steel tapes or wires in order to protect
corrosive gases emission in case of aluminium , aluminium alloy)
fire are required, they should be 2- INSULATION (usually PVC, PE, them against mechanical stressed and
insulated and sheathed with HFFR* XLPE , RUBBER, LSZH). damages.
material. 3- SHEATH (usually PVC, RUBBER, Standard specifications caters for a
Control cable can be used either for HFFR) wide range of choice for armour :
indoor installations as well for 4- ARMOUR (usually steel tapes,
outdoor installations. - Plain or galvanized steel tape
steel round or flat wires, aluminium
The distinction of the insulated tapes and wires). - Plain or galvanized flat steel wires
conductors is mainly realized by 5- OUTER PROTECTION OF CABLES - Galvanized round steel wires
numbering the insulation with white (protection against chemicals, as well - Aluminium flat wires or strips
numbers printed on black insulation. as against heat , flame, rodents, The final choice of the type of armour
The induction of any undesirable termites etc.).
signal, can be decreased or totally depends on the specifications.
avoided, by applying special CONDUCTORS Galvanized steel tapes are preferred by
screening material, such as Cable conductors are designed to users where the cables are supposed to
coppertapes or wires application, conform to a certain range of nominal be laid in aggressive environments
helped by special armour etc., in areas in graduated steps according to Where the armour is also used as an
order to reduce the level of the IEC 60228. The value of ohmic
disturbing signals so much, as to earth conductor, steel wire armour is
resistance at 20° C of each area, is also
minimize the risk of the primary given by IEC 60228. preferred.
signal alteration. Conductors are distinguished into Steel round or flat wires are usually

T U N I S I E 128 C Â B L E S
CONSTRUCTIONAL ELEMENTS OF POWER CABLES

applied as an armour in all cases, in Protection against rodents and sheathing materials in case of fire,
which the cables are subjected to termites achieve to the cable the propriety that
higher mechanical stresses, There are additives to the sheathing to be used in areas when strict safety
material which by their repellent or rat- standards have to be respected
especially longitudinal tensile stress
killing properties repel or kill termites
during cable laying or in case of or rodents, especially rats. Water proof cables
sandy soils and soils with very To secure longitudinal water tightness
weak compaction. Protection again Hydrocarbons throughout the cable length, a suitable
Single-core cables for AC and The cable used in oil and swelling tape is helically applied under
three-phase operation system, are petrochemical units is subject to the sheath. This tape is made up of a
various chemical products and matter that swells-up moisture and
not armoured as a rule, in order to
hydrocarbons. stop water tightness.
avoid excessive additional losses.
It is thus particularly important to
However in the cases where the protect them against the attacks of the
armour is necessary, an armour of following hydrocarbons groups :
non-magnetic material (copper or Aliphatic hydrocarbons
aluminium) has to be provided. Aromatic hydrocarbons
To resist to the aliphatic
hydrocarbons, cables are protected
OUTER PROTECTION OF CABLE
by PVC nitrate sheath.
Metal sheathed cables , as well as
armoured power cables must be
protected against corrosion, only Protection against fire
cables having an outer sheath of Particularly in public and industrial
PVC do not practically need any setting, when fire retardant qualities
protection against corrosion, as this are required in case of fire, filling and
sheath is by itself corrosion resistant sheathing materials should be flame
against nearly all chemicals or fire retardant. Moreover, the
eventually present in the soil. educed fumes, toxic and gases
remissions of HFFR filling and

T U N I S I E 129 C Â B L E S
CONDUCTORS CHARACTERISTICS

Solid copper and aluminum conductors Class 1

Approximate diameter (mm) Maximum electrical resistance at 20° C
TYPE Copper Aluminium
mm mm copper Aluminum
1,5 1,38 - 12,10 -
2,5 1,78 - 7,41 -
4 2,25 - 4,61 -
6 2,76 - 3,08 -
10 3,57 3,55 1,83 3,08
16 4,50 4,50 1,15 1,91
25 5,65 5,55 0,727 1,20
35 6,60 6,45 0,524 0,868
50 7,70 7,60 0,387 0,641
70 9,30 9,10 0,268 0,443
95 10,90 10,70 0,193 0,320
120 12,30 12,00 0,153 0,253
150 13,60 13,30 0,124 0,206
185 - 15,00 - 0,164
240 - 17,10 - 0,125
300 - 19,10 - 0,100

Stranded conductors class 2

Stranded circular Stranded compacted copper Maximum electrial
copper and aluminium and aluminium conductors resistance at 20° C
conductors ( /km )
TYPE Minimum Approximate
Minimum number of wires Approximate
conductor conductor copper Aluminium
number circular shape Sector shape diameter mm
of wires diameter
mm copper Alu copper Alu copper Alu

1,5 7 1,5 - - - - 1,70 - 12,10 -

2,5 7 2,1 - - - - 2,10 - 7,41 -
4 7 2,5 - - - - 2,55 - 4,61 -
6 7 3,1 - - - - 2,90 - 3,08 -
10 7 4,05 - - - - 3,80 - 1,83 3,08
16 7 5,1 6 6 - - 4,80 4,65 1,15 1,91
25 7 6,4 6 6 6 6 6,00 5,90 0,727 1,20
35 7 7,6 6 6 6 6 7,10 6,80 0,524 0,868
50 19 8,9 6 6 6 6 8,40 7,90 0,387 0,641
70 19 10,7 12 12 12 12 10,00 9,75 0,268 0,443
95 19 12,6 15 15 15 15 11,20 11,40 0,193 0,320
120 37 14,2 18 15 18 15 12,90 12,60 0,153 0,253
150 37 15,7 18 15 18 15 14,20 14,10 0,124 0,206
185 37 17,6 30 30 30 30 16 15,60 0,0991 0,164
240 61 20,2 34 30 34 30 18,30 17,90 0,0754 0,125
300 61 22,7 34 30 34 30 20,20 20,10 0,0601 0,100
400 61 25,6 53 53 53 53 - 23,20 0,0470 0,0778
500 61 28,8 53 53 53 53 26,60 27,40 0,0366 0,0605
630 91 32,8 53 53 53 53 32,40 29,60 0,0283 0,0469
800 91 37,0 53 53 - - 36,30 36,30 0,0221 0,0367
1000 91 41,6 53 53 - - - - 0,0176 0,0291

T U N I S I E 130 C Â B L E S
Stranded and flexible conductors class 5

Maximum diameter Approximate Maximum electrical resistance at 20° C

TYPE of wire diameter of ( /km )
mm conductor mm copper Tinned copper
0.5 0.21 0.9 39 40.1
0.75 0.21 1.1 26 26.7
1 0.21 1.3 19.5 20
1.5 0.26 1.5 13.3 13.7
2.5 0.26 1.8 7.98 8.21
4 0.31 2.4 4.95 5.09
6 0.31 3.0 3.30 3.39
10 0.41 4.0 1.91 1.95
16 0.41 5.1 1.21 1.24
25 0.41 6.6 0.780 0.795
35 0.41 7.8 0.554 0.565
50 0.41 9.3 0.386 0.393
70 0.51 11.5 0.272 0.277
95 0.51 13.1 0.206 0.210
120 0.51 14.7 0.161 0.164
150 0.51 16.7 0.129 0.132
185 0.51 18.6 0.106 0.108
240 0.51 21.0 0.0801 0.0817
300 0.51 23.6 0.0641 0.0654
400 0.51 27.5 0.0486 0.0495
500 0.61 31.3 0.0384 0.0391

Stranded and super flexible conductors class 6

Maximum diameter Approximate Maximum electrical resistance at 20° C

TYPE of wire diameter of ( /km )
mm conductor mm
Plain copper Tinned copper

0,5 0,16 0,9 39 40,1

0,75 0,16 1,1 26 26,7
1 0,16 1,3 19,5 20
1,5 0,16 1,6 13,3 13,7
2,5 0,16 2,3 7,98 8,21
4 0,16 2,9 4,95 5,09
6 0,21 3,4 3,30 3,39
10 0,21 4,5 1,91 1,95
16 0,21 5,1 1,21 1,24
25 0,21 6,6 0,780 0,795
35 0,21 8,6 0,554 0,565
50 0,31 10,2 0,386 0,393
70 0,31 12,3 0,272 0,277
95 0,31 14,2 0,206 0,210
120 0,31 15,0 0,161 0,164
150 0,31 17,0 0,129 0,132
185 0,41 18,7 0,106 0,108
240 0,41 21,4 0,081 0,0817
300 0,41 23,9 0,0641 0,0654

T U N I S I E 131 C Â B L E S
 INSULATION AND SHEATHING
M ATERIA L CHA RACTERISTICS

Insulating material characteristics

Insulating materials
Characteristics
PVC (Y) PE (2Y) XLPE (2X) Halogen free(H)
Density 1.35-1.5 0.94-0.98 0.92 1.4-1.6
Break down voltage Kv/mm(20° C) 25 70 50 25
Dielectric constant 3.6-6 2.3 4-6 3.4-5
Working temperature (° C) -30 to +70 -50 to +70 -35 to 90 -30 to +70
Flame resistance Self extinguishing flammable flammable Self extinguishing
Oxygen index (% O2) 23-42 <22 <22 <40
Heating value( Mj.kg) 17-25 42-44 42-44 17-22
Thermal conductivity (w.k-¹.m-¹) 0.17 0.3 0.3 0.17
Corrosive gases in case of fire Hydrogen chloride no no no
Tensile strength N/mm² 10-25 10-20 12.5-20 8-13
Elongation at break % 130-350 Medium 300-400 150-250
Shore hardness 70-95 A 43-50 D 40-45 D 65-95 A
Abrasion resistance Medium 400-600 Medium Medium
Water absorption % 0.4 0.1 0.1 0.2-1.5
Halogen free no yes yes yes

T U N I S I E 132 C Â B L E S
DRUM S CH A R ACT ERISTICS

Designation XBN ABN BBN CBN DBN EBN FBN GBN HBN

d1 : flange diameter mm 600 750 900 1050 1200 1400 1650 1900 2200
d2 : barrel diameter mm 350 350 450 550 650 800 960 1200 1400
u : traverse diameter mm 300 350 450 450 600 600 600 950 1000
d1 d2
H : overall width mm 385 435 555 555 705 720 735 1150 1220
d3 : bare diameter mm 42 82 82 82 82 82 82 82 82
Maximum load Kg 200 500 700 800 1200 1500 2500 4000 5000
U
net weight Kg 25 35 73 85 125 190 290 475 690

Capacity of drums
600 750 900 1050 1200 1400 1650 1900 2200
Type
X A B C D E F G H
Distance
50 50 50 50 50 50 50 50 50
to floor
D
mm Maximum cable lengths (m)
8 425 1170 2240 3235
10 267 800 1455 2070 3545
12 190 520 980 1340 2395 3200
14 131 365 720 1015 1800 2270 3390
16 88 279 515 755 1380 1760 2540
18 79 223 415 620 1040 1350 2005
20 172 320 490 870 1135 1580 3250
22 127 250 400 710 935 1320 2545
24 121 230 315 585 780 1125 2130 3050
26 90 185 257 470 640 945 1795 2625
28 175 248 435 510 775 1485 2225
30 130 191 355 490 660 1410 1910
32 180 325 380 595 1175 1620
34 135 257 365 495 960 1530
36 125 244 287 470 930 1265
38 116 184 271 375 770 1230
40 114 184 271 375 715 1030
42 80 174 206 355 685 955
44 163 191 275 550 785
46 125 191 275 525 755
48 115 178 257 500 725
50 115 178 209 500 725
52 107 126 190 385 575
54 107 126 190 365 550
56 98 115 174 345 520
58 115 174 345 520
60 115 135 325 400
64 121 237 375
68 108 221 350
72 108 221 254
80 212
84 197
88 197
90 197

The maximum cable length

(G = Distance to floor)
N1 and N2 should be round down
is calculated by the formula:

T U N I S I E 133 C Â B L E S
ELECTRICAL CHARACTERISTICS

Rigid copper and aluminium cables unarmoured 1 KV

RESISTANCE ( /km)
Reactance IMPEDANCE ( /km) at 50 Hz and 90° C
for cos
TYPE Continuous current alternative ( / km)
current
Rc 20° C Rc 90° C at 90° C at 50 Hz - L 1 0.8 0.5 0.3
Multi-pole copper cables
1,5 12,10 15,43 15,43 0,107 15,43 12.41 7,81 4,73
2,5 7,41 9,45 9,45 0,100 9,45 7,62 4,81 2,93
4 4,61 5,88 5,88 0,094 5,88 4,76 3,02 1,85
6 3,08 3,93 3,93 0,088 3,93 3,19 2,04 1,26
10 1,83 2,33 2,33 0,0785 2,33 1,91 1,23 0,77
16 1,15 1,47 1,47 0,0754 1,47 1,22 0,80 0,51
25 0,727 0,927 0,927 0,0754 0,930 0,787 0,529 0,350
35 0,524 0,668 0,668 0,0754 0,672 0,580 0,399 0,272
50 0,387 0,493 0,494 0,0754 0,500 0,441 0,313 0,220
70 0,268 0,342 0,343 0,0722 0,350 0,318 0,234 0,172
95 0,193 0,246 0,247 0,0722 0,257 0,241 0,186 0,143
120 0,153 0,195 0,197 0,0722 0,210 0,201 0,161 0,128
150 0,124 0,158 0,16 0,0722 0,176 0,171 0,143 0,117
185 0,0991 0,1264 0,1291 0,0722 0,1479 0,1466 0,1271 0,1076
240 0,0754 0,0961 0,0997 0,0722 0,1232 0,1232 0,1124 0,0988
300 0,0601 0,0766 0,0812 0,0691 0,1066 0,1064 0,1004 0,0903
Single core copper cables
50 0,387 0,493 0,493 0,0880 0,501 0,448 0,323 0,232
70 0,268 0,342 0,343 0,0848 0,353 0,325 0,245 0,184
95 0,193 0,246 0,247 0,0848 0,261 0,249 0,197 0,155
120 0,153 0,195 0,196 0,0816 0,212 0,206 0,169 0,137
150 0,124 0,158 0,160 0,0816 0,180 0,177 0,151 0,126
185 0,0991 0,1264 0,1285 0,0816 0,1522 0,1518 0,1349 0,1164
240 0,0754 0,0961 0,0991 0,0785 0,1264 0,1264 0,1175 0,1046
300 0,0601 0,0766 0,0803 0,0785 0,1123 0,1113 0,1081 0,0990
400 0,0470 0,0599 0,0646 0,0785 0,1017 0,0988 0,1003 0,0943

Multi core aluminum cables

35 0,868 1,113 1,113 0,0754 1,115 0,936 0,622 0,406
50 0,641 0,822 0,822 0,0754 0,825 0,703 0,476 0,318
70 0,443 0,568 0,569 0,0722 0,574 0,499 0,347 0,240
95 0,320 0,410 0,411 0,0722 0,418 0,372 0,268 0,192
120 0,253 0,324 0,325 0,0722 0,333 0,304 0,225 0,166
150 0,206 0,264 0,265 0,0722 0,275 0,255 0,195 0,148
185 0,164 0,210 0,212 0,0722 0,224 0,213 0,168 0,132
240 0,125 0,160 0,162 0,0691 0,177 0,171 0,141 0,115
300 0,100 0,128 0,131 0,0691 0,148 0,146 0,125 0,105
Single core aluminum cables
50 0,641 0,822 0,822 0,0880 0,827 0,710 0,487 0,330
70 0,443 0,568 0,568 0,0848 0,574 0,505 0,357 0,251
95 0,320 0,410 0,411 0,0848 0,420 0,380 0,279 0,204
120 0,253 0,324 0,325 0,0816 0,335 0,309 0,233 0,175
150 0,206 0,264 0,265 0,0816 0,277 0,261 0,203 0,157
185 0,164 0,210 0,212 0,0816 0,227 0,218 0,176 0,141
240 0,125 0,160 0,162 0,0785 0,180 0,177 0,149 0,124
300 0,1000 0,1282 0,1304 0,0785 0,1522 0,1515 0,1332 0,1140
400 0,0778 0,0997 0,1027 0,0785 0,1293 0,1293 0,1193 0,1057

T U N I S I E 134 C Â B L E S
ELECTRICAL CHARACTERISTICS

Rigid copper and aluminium cables 1 KV armoured

RESISTANCE ( /km) IMPEDANCE ( /km) at 50 Hz and 90° C
REACTANCE
TYPE Continuous current ( / km) for cos
alternative
current at 50 Hz - L 1 0.8 0.5 0.3
Rc 20° C Rc 90° C
Multi core copper cables
1,5 12,10 15,43 15,43 0,122 15,43 12,42 7,82 4,74
2.,5 7,41 9,45 9,45 0,116 9,45 7,63 4,82 2,95
4 4,61 5,88 5,88 0,110 5,88 4,77 3,03 1,87
6 3,08 3.93 3,93 0,100 3,93 3,20 2,05 1,27
10 1,83 2,33 2,33 0,094 2,34 1,92 1,25 0,790
16 1,15 1,47 1,47 0,0911 1,47 1,23 0,81 0,53
25 0,727 0,927 0,927 0,0911 0,931 0,796 0,542 0,365
35 0,524 0,668 0,668 0,0911 0,674 0,589 0,413 0,287
50 0,387 0,493 0,494 0,0879 0,502 0,448 0,323 0,232
70 0,268 0,342 0,343 0,0879 0,354 0,327 0,247 0,187
95 0,193 0,246 0,247 0,0879 0,262 0,250 0,200 0,158
120 0,153 0,195 0,197 0,0879 0,216 0,210 0,175 0,143
150 0,124 0,158 0,16 0,0879 0,183 0,181 0,156 0,132
185 0,0991 0,1264 0,1291 0,0879 0,1562 0,1560 0,1407 0,1226
240 0,0754 0,0961 0,0997 0,0879 0,1330 0,1326 0,1260 0,1138
300 0,0601 0,0766 0,0812 0,0848 0,1174 0,1158 0,1140 0,1053
Multi core aluminium cables
35 0,868 1,113 1,113 0,0911 1,117 0,945 0,635 0,421
50 0,641 0,822 0,822 0,0879 0,827 0,710 0,487 0,330
70 0,443 0,568 0,569 0,0879 0,576 0,508 0,361 0,255
95 0,320 0,410 0,411 0,0879 0,421 0,382 0,282 0,207
120 0,253 0,324 0,325 0,0879 0,337 0,313 0,239 0,181
150 0,206 0,264 0,265 0,0879 0,279 0,265 0,209 0,163
185 0,164 0,210 0,212 0,0879 0,229 0,222 0,182 0,147
240 0,125 0,160 0,162 0,0879 0,185 0,183 0,157 0,133
300 0,100 0,128 0,131 0,0848 0,156 0,156 0,139 0,120

Flexible cables 450/750 V

RESISTANCE ( /km) REACTANCE IMPEDANCE ( /km) at 50 Hz and 90° C
TYPE Continuous current alternative ( / km) for cos
current at 50 Hz - L 1 0.8 0.5 0.3
Rc 20° C Rc 90° C
Multi core copper cables
1 19,5 24,9 24,9 0,110 24,9 20 12,5 7,6
1,5 13,3 17,0 17,0 0,104 17,0 13,6 8,6 5,2
2,5 7,98 10,18 10,18 0,100 10,18 8,2 5,17 3,15
4 4,95 6,31 6,31 0,094 6,31 5,11 3,24 1,98
6 3,30 4,21 4,21 0,091 4,21 3,42 2,18 1,35
10 1,91 2,44 2,44 0,0879 2,44 2,00 1,29 0,81
16 1,21 1,54 1,54 0,0816 1,55 1,28 0,84 0,54
25 0,780 0,995 0,995 0,0816 0,998 0,845 0,568 0,376
35 0,554 0,706 0,706 0,0785 0,711 0,612 0,421 0,287
50 0,386 0,492 0,493 0,0785 0,499 0,442 0,315 0,223
70 0,272 0,347 0,347 0,0785 0,356 0,325 0,242 0,179
95 0,206 0,263 0,264 0,0785 0,275 0,258 0,200 0,154
Multi core aluminium cables
50 0,386 0,492 0,492 0,0973 0,502 0,452 0,330 0,240
70 0,272 0,347 0,348 0,0973 0,361 0,337 0,258 0,197
95 0,206 0,263 0,264 0,0973 0,281 0,269 0,216 0,172
120 0,161 0,205 0,206 0,0942 0,227 0,222 0,185 0,152
150 0,129 0,164 0,166 0,0911 0,189 0,187 0,162 0,137
185 0,106 0,135 0,137 0,0911 0,165 0,164 0,147 0,128
240 0,0801 0,1021 0,1044 0,0911 0,1385 0,1382 0,1311 0,1182
300 0,0641 0,0817 0,0846 0,0879 0,122 0,1204 0,1184 0,1092

T U N I S I E 135 C Â B L E S
GUIDE FOR SELECTION OF LOW VOLTGE CABLE

Introduction produce cable sizing waterfall The characteristics of the load

Cable sizing methods do differ charts for groups of cables with that the cable will supply, which
across international standards (e.g. similar characteristics (e.g. cables
includes: Load type: motor or
IEC, NEC, BS, etc) and some installed on ladder feeding
induction motors). feeder.
standards emphasise certain
things over others. However the Three phase, single phase or DC
general principles underlying any System / source voltage
General Methodology
cable sizing calculation do not Full load current (A) - or calculate
change. In this article, a general All cable sizing methods more or
this if the load is defined in terms
methodology for sizing cables is less follow the same basic six step
first presented and then the of power (kW)
process:
specific international standards are Full load power factor (pu)
introduced. 1- Gathering data about the
cable, its installation conditions, the Locked rotor or load starting
load that it will carry, etc current (A).
Why do the calculation? 2- Determine the minimum cable Starting power factor (pu)
The proper sizing of an electrical size based on continuous current Distance / length of cable run
(load bearing) cable is important carrying capacity.
from source to load - this length
to ensure that the cable can: 3- Determine the minimum cable should be as close as possible to
size based on voltage drop
- Operate continuously under full considerations. the actual route of the cable and
load without being damaged. include enough contingency for
4- Determine the minimum cable
- Withstand the worst short size based on short circuit vertical drops / rises and
circuits currents flowing through temperature rise. termination of the cable tails.
the cable. 5- Determine the minimum cable
- Provide the load with a suitable size based on earth fault loop
voltage (and avoid excessive impedance.
voltage drops). 6- Select the cable based on the
highest of the sizes calculated in
- (optional) Ensure operation of
step 2, 3, 4 and 5.
protective devices during an earth
fault.
Step 1: Data Gathering
The first step is to collate the
When to do the calculation?
relevant information that is
This calculation can be done
required to perform the sizing
individually for each power cable
calculation. Typically, you will
that needs to be sized, or
need to obtain the following data:
alternatively, it can be used to
Load Details

T U N I S I E 136 C Â B L E S
GUIDE FOR SELECTING LOW VOLTAGE ELECTRIC CABLE

Cable Construction spaced Cables with larger conductor cross-

The basic characteristics of the - Soil thermal resistivity (for sectional areas (i.e. more copper or
cable's physical construction, underground cables) aluminium) have lower resistive
which includes: - Depth of laying (for losses and are able to dissipate the
- Conductor material - normally underground cables) heat better than smaller cables.
copper or aluminium Therefore a 16 mm2 cable will have a
- For single core three-phase
- Conductor shape - e.g. circular higher current carrying capacity than a
cables, are the cables installed in
or shaped. 4 mm² cable.
trefoil or laid flat?
- Conductor type - e.g. stranded
or solid. Step 2: Cable Selection Based
- Conductor surface coating - on Current Rating
e.g. plain (no coating), tinned,
Current flowing through a cable
silver or nickel.
generates heat through the
- Insulation type - e.g. PVC, XLPE, resistive losses in the conductors,
EPR. dielectric losses through the
- Number of cores - single core insulation and resistive losses from
or multicore (e.g. 2C, 3C or 4C). current flowing through any cable
screens / shields and armouring.
Installation Conditions
How the cable will be installed, The component parts that make
which includes: up the cable (e.g. conductors,
- Above ground or insulation, bedding, sheath,
underground. armour, etc) must be capable of
- Installation / arrangement - e.g. withstanding the temperature rise
for underground cables, is it and heat emanating from the
directly buried or buried in cable. The current carrying
conduit? for above ground capacity of a cable is the maximum
cables, is it installed on cable tray / current that can flow continuously
ladder, against a wall, in air, etc. through a cable without damaging
- Ambient or soil temperature of the cable's insulation and other
the installation site. components (e.g. bedding,
sheath, etc). It is sometimes also
- Cable bunching, i.e. the number
referred to as the continuous
of cables that are bunched
current rating or ampacity of a
together.
cable.
- Cable spacing, i.e. whether
cables are installed touching or

T U N I S I E 137 C Â B L E S
 Base Current Ratings

Table A.52-10 (52-C9) - Current-carrying capacities in amperes for installation

methods E, F and G of table A.52-1 (52-B1) - PVC insulation/Copper conductors
Conductor temperature: 70 ° C/Reference ambient temperature: 30 ° C
Installation methods of table A.52-1
Multi-core cables Single-core cables
Nominal Three Three loaded conductors, flat
Three Two loaded
cross- Two loaded loaded conductors loaded Touching Spaced
selectional conductors conductors touching conductors Horizontal Vertical
trefoil
area of
conductor
mm²

Method E Method E Method F Method F Method F Method G Method G

1 2 3 4 5 6 7 8
1,5 22 18,5 - - - - -
2,5 30 25 - - - - -
4 40 34 - - - - -
6 51 43 - - - - -
10 70 60 - - - - -
16 94 80 - - - - -
25 119 101 131 110 114 146 130
35 148 126 162 137 143 181 162
50 180 153 196 167 174 219 197
70 232 196 251 216 225 281 254
95 282 238 304 264 275 341 311
120 328 276 352 308 321 396 362
150 379 319 406 356 372 456 419
185 434 364 463 409 427 521 480
240 514 430 546 485 507 615 569
300 593 497 629 561 587 709 659
400 - - 754 656 689 852 795
500 - - 868 749 789 982 920
630 - - 1 005 855 905 1 138 1 070

NOTE: Circular conductors are assumed for sizes up to and including 16 mm². Values for larger sizes relate to shaped
conductors and may safely be applied to circular conductors.

Table 1. Example of base current rating table (Excerpt from IEC 60364-5-52)

International standards and manufacturers of cables will quote base current ratings of different types of cables in
tables such as the one shown on the right. Each of these tables pertain to a specific type of cable construction (e.g.
copper conductor, PVC insulated, 0.6/1kV voltage grade, etc) and a base set of installation conditions (e.g. ambient
temperature, installation method, etc). It is important to note that the current ratings are only valid for the quoted
types of cables and base installation conditions.
In the absence of any guidance, the following reference based current ratings may be used.

T U N I S I E 138 C Â B L E S
 Installed Current Ratings loads, the upstream protective across it, which can be derived by
device (fuse or circuit breaker) is Ohm's Law (i.e. V = IZ). The voltage drop
When the proposed installation
typically selected to also protect the will depend on two things:
conditions differ from the base
cable against damage from thermal
conditions, derating (or correction)
overload. The protective device must
factors can be applied to the base - Current flow through the cable – the
therefore be selected to exceed the
current ratings to obtain the actual higher the current flow, the higher the
full load current, but not exceed the
installed current ratings.
cable's installed current rating, i.e. this voltage drop.
International standards and cable inequality must be met:
manufacturers will provide
- Impedance of the conductor – the
derating factors for a range of Il < Ip < kc larger the impedance, the higher the
installation conditions, for example
Where voltage drop.
ambient / soil temperature,
grouping or bunching of cables, soil Il is the full load current (A)
thermal resistivity, etc. The installed Ip is the protective device rating (A) Cable Impedances
current rating is calculated by
multiplying the base current rating
kc is the installed cable current rating (A) The impedance of the cable is a
with each of the derating factors, i.e. function of the cable size (cross-
Motors sectional area) and the length of the
Ic = Ib.kd cable. Most cable manufacturers will
where Motors are normally protected by a
separate thermal overload (TOL) relay quote a cable's resistance and
and therefore the upstream reactance in Ω /km. The following typical
Ic is the installed current rating (A)
protective device (e.g. fuse or circuit cable impedances for low voltage AC
Ib is the base current rating (A) breaker) is not required to protect the and DC single core and multicore cables
cable against overloads. As a result, can be used in the absence of any other
kd are the product of all the cables need only to be sized to cater data.
derating factors for the full load current of the motor,
i.e.
For example, suppose a cable
had an ambient temperature
Il < Ic Calculating Voltage Drop
For AC systems, the method of
derating factor of kamb = 0.94 and a calculating voltage drops based on load
Where
grouping derating factor of kg =
0.85, then the overall derating factor
Il is the full load current (A) power factor is commonly used. Full
kd = 0.94x0.85 = 0.799. For a cable Ic is the installed cable current rating (A) load currents are normally used, but if
with a base current rating of 42A, the load has high startup currents (e.g.
the installed current rating would be motors), then voltage drops based on
Ic = 0.799x42 = 33.6A. Of course, if there is no separate thermal starting current (and power factor if
overload protection on the motor, then applicable) should also be calculated.
the protective device needs to be taken
In the absence of any guidance, into account as per the case for feeders For a three phase system:
the following reference derating above.
factors may be used.

Cable Selection and Step 3: Voltage Drop V3 = 3I ( Rc cos + Xc sin ) L

Coordinaton with Protective
1000
A cable's conductor can be seen as
Devices an impedance and therefore
Feeders whenever current flows through a
When sizing cables for non-motor cable, there will be a voltage drop

T U N I S I E 139 C Â B L E S
 Where Rc is the dc resistance of the speed up the selection of similar type
is the three phase voltage cable (Ω /km) cables.
V3
drop (V) L is the length of the cable (m) The maximum cable length that will
achieve this can be calculated by re-
I is the nominal full load or
arranging the voltage drop equations and
starting current as Maximum Permissible Voltage
Rc substituting the maximum permissible
applicable (A) Drop voltage drop (e.g. 5% of 415V nominal
Xc is the ac resistance of the It is customary for standards (or voltage = 20.75V). For a three phase
cable (Ω /km) clients) to specify maximum permissible system:
cos is the ac reactance of the voltage drops, which is the highest 1000 V3
cable (Ω /km) voltage drop that is allowed across a Lmax =
is the load power factor cable. Should your cable exceed this 3I ( Rc cos + Xc sin )
L voltage drop, then a larger cable size
(pu) Where
should be selected.
is the length of the cable (m) Lmax is the maximum length of the
Maximum voltage drops across a cable (m)
For a single phase system: cable are specified because load V3 is the maximum permissible three
consumers (e.g. appliances) will have an
V1 = 2I ( Rc cos + Xc sin ) L input voltage tolerance range. This
phase voltage drop (V)
1000 means that if the voltage at the appliance I is the nominal full load or starting
is lower than its rated minimum voltage, current as applicable (A)
Where then the appliance may not operate
Rc is the ac resistance of the cable
V1 is the single phase voltage correctly.
drop (V) (Ω /km)

I is the nominal full load or In general, most electrical equipment Xc is the ac reactance of the cable
starting current as will operate normally at a voltage as low (Ω /km)
applicable (A) as 80% nominal voltage. For example, if
cos is the load power factor (pu)
is the ac resistance of the the nominal voltage is 230VAC, then
Rc
most appliances will run at >184VAC. For a single phase system:
cable (Ω /km)
Cables are typically sized for a more
Xc is the ac reactance of the conservative maximum voltage drop, in 1000 V1
cable (Ω /km) the range of 5 – 10% at full load.
Lmax =
2I ( Rc cos + Xc sin )
cos is the load power factor
(pu) Calculating Maximum Cable Where
L is the length of the cable Length due to Voltage Drop Lmax is the maximum length of the
(m) It may be more convenient to
cable (m)
calculate the maximum length of a cable
is the maximum permissible
For a DC system: Vdc = 2I Rc L for a particular conductor size given a V1
1000 maximum permissible voltage drop (e.g. single phase voltage drop (V)
5% of nominal voltage at full load) rather
Where I is the nominal full load or starting
than the voltage drop itself. For
Vdc is the dc voltage drop (V) example, by doing this it is possible to current as applicable (A)
I is the nominal full load or construct tables showing the maximum Rc is the ac resistance of the cable
starting current as applicable lengths corresponding to different
(Ω /km)
cable sizes in order to
(A)

T U N I S I E 140 C Â B L E S
Xc is the ac reactance of the drop (e.g. 5% of nominal voltage at full that it is expected to see.
load) rather than the voltage drop itself.
cable (Ω /km)
For example, by doing this it is possible Minimum Cable Size Due to Short
cos is the load power factor (pu) to construct tables showing the Circuit Temperature Rise
maximum lengths corresponding to
For a DC system: The minimum cable size due to short
different cable sizes in order to speed
circuit temperature rise is typically
1000 Vdc up the selection of similar type cables. calculated with an equation of the form:
Lmax = The maximum cable length that will
2I Rc achieve this can be calculated by re-
A = i²t
arranging the voltage drop equations k
Maximum Permissible Voltage and substituting the maximum Where
Drop permissible voltage drop (e.g. 5% of
A is the minimum cross-sectional area
It is customary for standards (or 415V nominal voltage = 20.75V). For a
of the cable (mm2)
c l i e n t s ) t o s p e c i f y m a x i m u m three phase system:
permissible voltage drops, which is i is the prospective short circuit
the highest voltage drop that is Where
current (A)
allowed across a cable. Should your L max is the maximum length of the
cable exceed this voltage drop, then a cable (m) t is the duration of the short circuit (s)
larger cable size should be selected. k is a short circuit temperature rise
V
dc is the maximum permissible dc
constant
Maximum voltage drops across a
voltage drop (V)
cable are specified because load I is the nominal full load or
The temperature rise constant is
consumers (e.g. appliances) will have starting current as applicable (A) calculated based on the material
an input voltage tolerance range. This properties of the conductor and the
Rc is the dc resistance of the cable
means that if the voltage at the initial and final conductor temperatures
appliance is lower than its rated (Ω /km) (see the derivation here). Different
minimum voltage, then the appliance international standards have different
L is the length of the cable (m) treatments of the temperature rise
may not operate correctly.
constant, but by way of example, IEC
Step 4: 60364-5-54 calculates it as follows:
In general, most electrical equipment
Short Circuit Temperature Rise
will operate normally at a voltage as
During a short circuit, a high amount
low as 80% nominal voltage. For
of current can flow through a cable for (
example, if the nominal voltage is
230VAC, then most appliances will run
at >184VAC. Cables are typically sized
for a more conservative maximum
a short time. This surge in current flow
causes a temperature rise within the
cable. High temperatures can trigger
k = 226 ln
( 1+
f
234.5 +
- i

unwanted reactions in the cable

voltage drop, in the range of 5 – 10% at
(for copper conductors)
full load. insulation, sheath materials and other
components, which can prematurely
Calculating Maximum Cable degrade the condition of the cable. (
Length due to Voltage Drop
It may be more convenient to
calculate the maximum length of a
As the cross-sectional area of the
cable increases, it can dissipate higher
fault currents for a given temperature
k = 148 ln
( 1+
f
228 +
- i

rise. Therefore, cables should be sized

cable for a particular conductor size (for copper conductors)
given a maximum permissible voltage
to withstand the largest short circuit

T U N I S I E 141 C Â B L E S
 voltage is 230VAC, then most Step 5:
Where
appliances will run at >184VAC. Cables Earth Fault Loop Impedance
i is the initial conductor
temperature (deg C) are typically sized for a more
Sometimes it is desirable (or
is the final conductor conservative maximum voltage drop, in
i necessary) to consider the earth fault
temperature (deg C) the range of 5 – 10% at full load.
loop impedance of a circuit in the sizing
of a cable. Suppose a bolted earth fault
Initial and Final Conductor Calculating Maximum Cable occurs between an active conductor
Temperatures Length due to Voltage Drop and earth. During such an earth fault, it is
The initial conductor temperature It may be more convenient to desirable that the upstream protective
is typically chosen to be the calculate the maximum length of a cable device acts to interrupt the fault within a
maximum operating temperature of maximum disconnection time so as to
for a particular conductor size given a
the cable. The final conductor
maximum permissible voltage drop (e.g. protect against any inadvertent contact
temperature is typically chosen to be
the limiting temperature of the 5% of nominal voltage at full load) rather to exposed live parts.
insulation. In general, the cable's than the voltage drop itself. For
insulation will determine the example, by doing this it is possible to Ideally the circuit will have earth fault
maximum operating temperature construct tables showing the maximum protection, in which case the protection
and limiting temperatures.
lengths corresponding to different will be fast acting and well within the
cable sizes in order to speed up the maximum disconnection time. The
As a rough guide, the following selection of similar type cables. maximum disconnection time is chosen
temperatures are common for the The maximum cable length that will so that a dangerous touch voltage does
different insulation materials: achieve this can be calculated by re- not persist for long enough to cause
arranging the voltage drop equations injury or death. For most circuits, a
Maximum Permissible Voltage and substituting the maximum maximum disconnection time of 5s is
permissible voltage drop (e.g. 5% of sufficient, though for portable
Drop
415V nominal voltage = 20.75V). For a equipment and socket outlets, a faster
It is customary for standards (or
three phase system:
clients) to specify maximum disconnection time is desirable (i.e. <1s
permissible voltage drops, which is and will definitely require earth fault
the highest voltage drop that is Max protection).
Operating Limiting
allowed across a cable. Should your Material Temp. °C
Temp. ° C
cable exceed this voltage drop, then a However for circuits that do not have
PVC 75 160
larger cable size should be selected. earth fault protection, the upstream
EPR 90 250
XLPE 90 250 protective device (i.e. fuse or circuit
Maximum voltage drops across a breaker) must trip within the maximum
cable are specified because load disconnection time. In order for the
consumers (e.g. appliances) will have Short Circuit Energy protective device to trip, the fault
an input voltage tolerance range. This The short circuit energy is normally current due to a bolted short circuit
means that if the voltage at the chosen as the maximum short circuit must exceed the value that will cause
appliance is lower than its rated that the cable could potentially the protective device to act within the
minimum voltage, then the appliance experience. However for circuits with maximum disconnection time.
may not operate correctly. current limiting devices (such as HRC
fuses), then the short circuit energy
In general, most electrical chosen should be the maximum
equipment will operate normally at a prospective let-through energy of the
voltage as low as 80% nominal protective device, which can be
voltage. For example, if the nominal found from manufacturer data.

T U N I S I E 142 C Â B L E S
For example, suppose a circuit is Where
protected by a fuse and the
1000 Vo
Zs is the earth fault loop Lmax =
maximum disconnection time is 5s, impedance (Ω ) IA ( Rc+ Re )² + ( Xc+ Xe )²
then the fault current must exceed
Zc is the impedance of the active
the fuse melting current at 5s (which
can be found by cross-referencing conductor (Ω ) Where
the fuse time-current curves). Ze is the impedance of the earth Lmax is the maximum cable length (m)
By simple application of Ohm's law: conductor (Ω ) Vo is the phase to earth voltage at

Vo the protective device (V)

IA = Assuming that the active and earth IA is the earth fault current required
Zs
Where conductors have identical lengths, the to trip the protective device
earth fault loop impedance can be within the minimum
is the earth fault current
IA calculated as follows:
required to trip the protective disconnection time (A)
device within the minimum Zs = L ( Rc+ Re )² + ( Xc+ Xe )² Rc and Re are the ac resistances of the
1000 active and earth conductors
disconnection time (A)
respectively (Ω /km)
is the phase to earth voltage at
Where Xc and Xe are the reactances of the
Vo the protective device (V)
is the impedance of the earth
L is the length of the cable (m) active and earth conductors
Zs fault loop (Ω Rc and Re are the ac resistances of respectively (Ω /km)
)
the active and earth conductors
respectively (Ω /km) Note that the voltage Vo at the
It can be seen from the equation
Xc and Xe are the reactances of the protective device is not necessarily the
above that the impedance of the
active and earth conductors nominal phase to earth voltage, but
earth fault loop must be sufficiently
respectively (Ω /km) usually a lower value as it can be
low to ensure that the earth fault
downstream of the main busbars. This
current can trip the upstream
Maximum Cable Length voltage is commonly represented by
protection.
applying some factor to the nominal
The maximum earth fault loop
voltage. A conservative value of
impedance can be found by
The Earth Fault Loop c = 0.8 can be used so that:
re-arranging the equation above
The earth fault loop can consist of
Vo = cVn = 0.8 Vn
various return paths other than the Zs max = Vo
earth conductor, including the cable IA
Where Where Vn is the nominal phase to earth
armour and the static earthing
voltage (V)
connection of the facility. However Zs is the maximum earth fault loop
for practical reasons, the earth fault impedance (Ω )
loop in this calculation consists only Worked Example
Vo is the phase to earth voltage at
of the active conductor and the In this example, we will size a cable for
the protective device (V)
earth conductor. a 415V, 30kW three-phase motor from
IA is the earth fault current required the MCC to the field.
to trip the protective device
The earth fault loop impedance can
be found by: within the disconnection time (A) Step 1: Data Gathering
The maximum cable length can The following data was collected for
Zs = Zc + Ze therefore be calculated by the the cable to be sized:
following: :

T U N I S I E 143 C Â B L E S
 - Cable type: Cu/PVC/GSWB/PVC, Step 3: Voltage Drop a good idea to also check that the cable
3C+E, 0.6/1kV Suppose a 25 mm² cable is selected. can withstand the short circuit
If the maximum permissible voltage temperature rise for for a 5s fault. The
- Operating temperature: 75C 80A motor fuse has a 5s melting current
drop is 5%, is the cable suitable for a
- Cable installation: above ground of 550A. The short circuit temperature
run length of 90m?
on cable ladder bunched together rise is thus:
with 3 other cables on a single layer
A 25 mm² cable has an ac
and at 30C resistance of 0.884 Ω /km and an ac A = 550² x 5 = 11.047mm²
ambient temperature reactance of 0.0895 Ω /km. The 111.329
voltage drop across the cable is:
- Cable run: 90m (including tails) Therefore, our 25 mm² cable is still
- Motor load: 30kW, 415V three V 90 suitable for this application.
d = x 3 x 61 x 0.884 x
phase, full load current = 61A, 1000
power factor = 0.85 0.85 + 0.0895 ( cos -1
Step 5: Earth Fault Loop
- Protection: aM fuse of rating = (0.85) ) = 7.593V
Impedance
80A, max prospective fault I²t = 90
Suppose there is no special earth fault
A²s , 5s melt time = 550A A voltage drop of 7.593V is protection for the motor and a bolted
equivalent to 7.593 single phase to earth fault occurs at the
= 1.83% motor terminals. Suppose that the earth
Step 2: Cable Selection Based 415 conductor for our 25 mm² cable is 10
on Current Rating which is lower than the maximum mm². If the maximum disconnection
Suppose the ambient permissible voltage time is 5s, is our 90m long cable suitable
based on earth fault loop impedance?
temperature derating is 0.89 and the dorp of 5%. Therefore the cable is
grouping derating for 3 bunched suitable for the motor based on
voltage drop considerations. The 80A motor fuse has a 5s melting
cables on a single layer is 0.82. The current of 550A. The ac resistances of
overall derating factor is 0.89 X 0.82 the active and earth conductors are
= 0.7298. Given that a 16 mm² and 25 Step 4: Short Circuit 0.884 Ω /km and 2.33 Ω /km)
mm² have base current ratings of respectively. The reactances of the
Temperature Rise active and earth conductors are 0.0895
80A and 101A respectively (based
The cable is operating normally at Ω /km and 0.0967 Ω /km) respectively.
on Reference Method E), which 75C and has a prospective fault The maximum length of the cable
cable should be selected based on capacity (I²t) of 90,000 A2s. What is allowed is calculated as:
current rating considerations? the minimum size of the cable based
on short circuit temperature rise?
(1000)(0.8)(240)
The installed current ratings for 16 Lmax = = 108.43m
PVC has a limiting temperature of 550 (0.884 + 2.33)² + (0.0895 + 0.0967)²
mm² and 25 mm² is 0.7298 X 80A = 160C. Using the IEC formula, the short
58.38A and 0.7298 X 101A = 73.71A circuit temperature rise constant is
respectively. Given that the full load 111.329. The minimum cable size due The cable run is 90m and the
current of the motor is 61A, then the to short circuit temperature rise is maximum length allowed is 108m,
therefore: therefore our cable is suitable based on
installed current rating of the 16 mm²
earth fault loop impedance. In fact, our
cable is lower than the full load 25 mm² cable has passed all the tests
current and is not suitable for A = 90, 000 = 2.695mm² and is the size that should be selected.
continuous use with the motor. The 111.329
25 mm² cable on the other hand has In this example, we also use the fuse
an installed current rating that for earth fault protection and it needs
exceeds the motor full load current, to trip within 5s, which is at the
and is therefore the cable that upperend of the adiabatic period
where the short circuit temperature
should be selected. rise equation is still valid. Therefore, it's

T U N I S I E 144 C Â B L E S
 Waterfall Charts
Load Rating (kw)

gMFuse Fating

415V 3-Phase Motor Cable Selection Chart (15% Starting, 5% Full Load Voltage Drop)
(A)

2.5 4 6 10 16 25 35 50 70 95 120 150 185 2x95 Conductors Size (mm²)

19.01 24.85 31.43 41.67 54.09 70.18 84.07 102.34 127.93 153.51 175.44 197.37 226.61 307.02 Current Rating (A)

1.1 4
1.5 6 355 407
2.2 10 240 275 449
3 10 240 275 449
4 16 130 149 243 370 411
5.5 16 130 149 243 370 411
7.5 20 104 119 194 296 329
11 32 78 90 146 222 246
15 40 129 215 335 487
18.5 50 174 272 395
22 63 229 332 427
30 80 244 313 390 495
37 100 254 316 401 480
45 125 260 330 394 447 488
55 160 270 323 366 399 434
75 200 237 268 293 318 473
90 200 224 244 265 394
110 250 217 323
132 355 269
150 400 237
160 400
185 500

Table 2. Example of a cable waterfall chart

Sometimes it is convenient to group together similar types of cables (for example, 415V PVC motor cables installed on
cable ladder) so that instead of having to go through the laborious exercise of sizing each cable separately, one can
select a cable from a pre-calculated chart.

These charts are often called "waterfall charts" and typically show a list of load ratings and the maximum of length of
cable permissible for each cable size. Where a particular cable size fails to meet the requirements for current carrying
capacity or short circuit temperature rise, it is blacked out on the chart (i.e. meaning that you can't choose it).

Preparing a waterfall chart is common practice when having to size many like cables and substantially cuts down the
time required for cable selection.

T U N I S I E 145 C Â B L E S
N O T E S
N O T E S
N O T E S
 C/R
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A member of One TECH Group

Headquarter : Les Berges du Lac - Cité El Khalij- Rue Loch Ness
I m m e u b l e " L e s A r c a d e s " - To u r A - B P 4 1 - 1 0 8 0 Tu n i s C e d e x
Te l . : ( + 2 1 6 ) 7 1 8 6 0 2 4 4 F a x : ( + 2 1 6 ) 7 1 8 6 0 5 7 1
Email : [email protected]
We b s i t e : w w w. t u n i s i e - c a b l e s . t n / w w w. o n e t e c h - g r o u p . c o m

Plant (Grombalia) : Zone industrielle 8030 Grombalia

Te l . : ( + 2 1 6 ) 7 2 2 5 5 0 2 2 F a x : ( + 2 1 6 ) 7 2 2 5 5 8 7 3

Plant (Bizerte) : Zone industrielle 7026 EL Azib - Bizerte

Te l . : ( + 2 1 6 ) 7 2 4 5 11 0 0 F a x : ( + 2 1 6 ) 7 2 4 5 1 2 8 5