Cable capacity of conduits and trunking
The following single-core p.v.c. insulated cables are to be run in a conduit 6 m long with a double set:
8 x 1,4 x 2.5 and 2 x 6 mm. Choose a suitable size.
Table 1- Cable factors (terms) for conduit and trunking
Type of
conductor
Conductor
c.s.a. (mm)
Factor for
Factor for
trunking pvc
conduit
insulation
Factor for trunking
thermosetting
insulation
Solid
1.0
16
3.6
3.8
Solid
1.5
22
8.0
8.6
Stranded
1.5
22
8.6
9.1
Solid
2.5
30
11.9
11.9
Stranded
2.5
30
12.6
13.9
Stranded
4.0
43
16.6
18.1
Stranded
6.0
58
21.2
22.9
Stranded
10.0
105
35.3
36.3
Stranded
16.0
145
47.8
50.3
Stranded
25.0
217
73.9
75.4
Table 2- Cable factors (terms) for straight runs up to 3m.
Type of conductor
Conductor c.s.a. (mm)
Cable factor
Solid
1.0
22
Solid
1.5
27
Solid
2.5
39
Stranded
1.5
31
Stranded
2.5
43
Stranded
4.0
58
Stranded
6.0
88
Stranded
10.0
146
Table 3- Conduit factors (terms)
Length of run between boxes (m)
1
Conduit, straight
10
16mm
290
290
290
171
171
167
158
150
20mm
460
460
460
286
278
270
256
244
25mm
800
800
800
514
500
487
463
442
32mm
1400
1400
1400
900
878
857
818
783
Conduit, one bend
16mm
188
177
167
158
150
143
130
120
20mm
303
286
270
256
244
233
213
196
25mm
543
514
487
463
442
422
388
258
32mm
947
900
857
818
783
750
692
643
Conduit, two bends
16mm
177
158
143
130
120
111
97
86
20mm
286
256
233
213
196
182
159
141
25mm
514
463
422
388 358
333
292
260
32mm
900
818
750
692
600
529
474
643
For 38mm conduit use the 32mm factor x 1.4.
For 50mm conduit use the 32mm factor x 2.6.
For 63mm conduit use the 32mm factor x 4.2.
Table 4 Trunking factors (terms)
Dimensions of trunking (mm x mm)
Factor
37.5 x 50
767
50 x 50
1037
25 x 75
738
37.5 x 75
1146
50 x 75
1555
75 x 75
2371
25 x 100
993
37.5 x 100
1542
50 x 100
2091
75 x 100
3189
100 x 100
4252
Consulting {Table 1} gives the following cable factors:
16 for 1 mm, 30 for 2.5 mm and 58 for 6 mm
Total cable factor is then
(8 x 16) + (4 x 30) + (2 x 58)
= 128 + 120 + 116 = 364
The terrn "bend" means a right angle bend or a double set.
{Table 3} gives a conduit factor for 20 mm conduit 6 m long with a double set as 233, which is
less than 364 and thus too small. The next size has a conduit factor of 422 which will be acceptable
since it is larger than 364.
The correct conduit size is 25 mm diameter.
The first conduit from a distribution board will be straight and 10 m long. It is to enclose 4 x
10 mm and 8 x 4 mm cables. Calculate a suitable size.
From {Table 1}, cable factors are 105 and 43 respectively. Total cable factor:
=(4 x 105) + (8 x 43) = 420 + 344 = 764
From ({Table 2}, a 10 m long straight 25 mm conduit has a factor of 442. This is too small, so
the next size, with a factor of 783 must be used.
The correct conduit size is 32 mm diameter.
A 1.5 m straight length of conduit from a consumer's unit encloses ten
1.5 mm and four 2.5 mm solid conductor p.v.c. insulated cables.
Calculate a suitable conduit size.
From ({Table 2} (which is for short straight runs of conduit) total cable factor will be:
= (10 x 27) + (4 x 39) = 426
Table 3
shows that 20 mm diameter conduit with a factor of 460 will be necessary.
Example
A length of trunking is to carry eighteen 10 mm, sixteen 6 mm,
twelve 4 mm, and ten 2.5 mm stranded single p.v.c. insulated cables.
Calculate a suitable trunking size.
The total cable factor for trunking is calculated with data from {Table 1}.
18 x 10mm at 36.3
= 18 x 36.3
= 653.4
16 x 6mm at 22.9
= 16 x 22.9
= 366.4
12 x 4mm at 15.2
= 12 x 15.2
= 182.4
10 x 2.5mm at 11.4
= l0 x ll.4
= 114.0
Total cable factor
= 1316.2
From the trunking factor {Table 4. }, two standard trunking sizes have factors slightly greater
than the cable factor, and either could be used .
They are 50 mm x 75 mm at 1555, and 37.5 mm x 100 mm at 1542.
2 - Ducting and trunking
Metal and plastic trunkings are very widely used in electrical installations. They must be manufactured
to comply with the relevant British Standards, and must be installed so as to ensure that they will not
be damaged by water or by corrosion (see {4.2.5}).
Table 4.13 Support spacings for trunking
Typical trunking size
(mm)
Metal
Insulating
Horizontal
Vertical
Horizontal
Vertical
Up to 25 x 25
0.75
1.0
0.5
0.5
Up to 50 x 25
1.25
1.5
0.5
0.5
Up to 50 x 50
1.75
2.0
1.25
1.25
Up to 100 x 50
3.0
3.0
1.75
2.0
If it is considered necessary to provide an additional protective conductor in parallel with steel
trunking, it must be run inside the trunking or the presence of steel between the live and protective
cables will often result in the reactance of the protective cable being so high that it will have little effect
on fault loop impedance. Trunking must be supported as indicated in {Table 4.13}. The table does not
apply to special lighting trunking which is provided with strengthened couplers. Where crossing a
building expansion joint a suitable flexible joint should be included.
Where trunking or conduit passes through walls or floors the hole cut must be made good after the
first fix on the construction site to give the partition the same degree of fire protection it had before the
hole was cut. Since it is possible for fire to spread through the interior of the trunking or conduit, fire
barriers must be inserted as shown in {Fig 4.18}. An exception is conduit or trunking with a crosssectional area of less than 710 mm, so that conduits up to 32 mm in diameter and trunking up to 25
mm x 25 mm need not be provided with fire barriers. During installation, temporary fire barriers must
be provided so that the integrity of the fire prevention system is always maintained.
Since trunking will not be solidly packed with cables (see {4.5.3}) there will be room for air movement.
A very long vertical trunking run may thus become extremely hot at the top as air heated by the cables
rises; this must be prevented by barriers as shown in {Fig 4.19}. In many cases the trunking will pass
through floors as it rises, and the fire stop barriers needed will also act as barriers to rising hot air.
Lighting trunking is being used to a greater extent than previously In many cases, it includes copper
conducting bars so that luminaires can be plugged in at any point, especially useful for display
lighting.
The considerably improved life, efficiency and colour rendering properties of extra-low voltage
tungsten halogen lamps has led to their increasing use, often fed by lighting trunking. It is important
here to remember that whilst the voltage of a 12 V lamp is only one twentieth of normal mains
potential, the current for the same power inputs will be twenty times greater. Thus, a trunking feeding
six 50 W 12 V lamps will need to he rated at 25 A.
Breaker or Fuse
Type
Fuses and FixedTrip Circuit
Breakers**
Conditions
Rating
The standard ampere
ratings for fuses and
inverse time circuit
breakers shall be
considered as follows:
15, 20, 25, 30, 35, 40,
45, 50, 60, 70, 80, 90,
100, 110, 125, 150, 175,
200, 225, 250, 300, 350,
400, 450, 500, 600, 700,
800, 1000, 1200, 1600,
2000, 2500, 3000, 4000,
5000, and 6000 amperes.
Additional standard
ampere ratings for fuses
shall be 1, 3, 6, 10, and
601.
Adjustable-Trip
Circuit
Breakers**
Breakers have external
means for adjusting the
current setting (long-time
pickup setting), not meeting
= the maximum setting
possible.
the requirements of
Restricted Access breakers in
below.
Restricted Access
Adjustable-Trip
Circuit Breakers
**(see fig.1)
Breakers that have restricted
access to the adjusting
means. Restricted access
shall be defined as located
behind one of the following:
Removable and
sealable covers over the
adjusting means,
Bolted equipment
enclosure doors,
Locked doors
accessible only to qualified
personnel.
= the adjusted current
setting (long-time pickup
setting).
Notes:
* The use of fuses and inverse time circuit breakers with nonstandard ampere
ratings shall be permitted.
** A combination of a current transformer and overcurrent relay shall be considered
equivalent to an overcurrent trip unit.
- The set long-time pickup rating is the opposite to the instantaneous trip rating.
Multipole or Single-Pole Circuit breakers
Circuit breakers (as Overcurrent Device) shall open all ungrounded conductors of the
circuit both manually and automatically. (see fig.2)
Exception: single-pole circuit breakers, with identified handle ties, shall be permitted as
the protection for each ungrounded conductor as in the blow table.
Case
Multiwire Branch
Circuits(see fig.3)
Grounded Single-Phase
Alternating-Current
Circuits (see fig.4)
3-Phase and 2-Phase
Systems (see fig.4)
Condition
Serve only single-phase line-to neutral loads.
individual single-pole circuit breakers
rated 120/240 volts ac,
For line-to-line connected loads for singlephase circuits.
For line-to-line loads in 4-wire, 3-phase
systems or 5-wire, 2-phase systems,
The systems have a grounded neutral point
and the voltage to ground does not exceed 120
volts.
3-Wire Direct-Current
Circuits
Individual single-pole circuit breakers
rated 125/250 volts dc,
For line-to-line connected loads for 3-wire,
direct current circuits supplied from a system
with a grounded neutral where the voltage to
ground does not exceed 125 volts.
Circuit breaker used as a switch
15- or 20-ampere Circuit breakers used as switches in 120-volt and 277-volt
fluorescent lighting circuits shall be listed and shall be marked SWD.
15- or 20-ampere Circuit breakers used as switches in high-intensity discharge
lighting circuits shall be listed and shall be marked as HID.
Circuit breakers marked HID can be used for switching both high-intensity
discharge and fluorescent lighting loads; however, a circuit breaker marked SWD can be
used only as a switching device for fluorescent lighting loads.
Permissible Usages for Fuses
fuses shall be permitted to be used in certain circuits as per the following Table:
Fuse Type
Plug fuses of the
Edison-base
type(see fig.5)
Type S fuses (see
fig.5)
Cartridge fuses
and fuseholders
of the 300-volt
type (see fig.6)
Ratings
Permissible Usages
Shall be classified
at not over 125
volts and 30
amperes and
below.
Plug fuses shall be permitted to be
used in the following circuits:
Circuits not exceeding 125
volts between conductors (such as
circuits supplied by 120/240-volt,
single-phase, 3-wire systems and by
Shall be classified 208Y/120-volt, 3-phase, 4-wire
at not over 125
systems),
volts and 0 to 15
Circuits supplied by a system
amperes, 16 to
having a grounded neutral point
20 amperes, and
where the line-to-neutral voltage
21 to 30
does not exceed 150 volts.
amperes.
Shall be classified shall be permitted to be used in the
at not over 300
following circuits:
volts.
Circuits not exceeding 300
volts between conductors,
Single-phase line-to-neutral
circuits supplied from a 3-phase, 4-
wire, solidly grounded neutral
source where the line-to-neutral
voltage does not exceed 300 volts
Rule#1: Location of overcurrent protection devices (OCPDs)
Overcurrent protection shall be provided in each ungrounded circuit conductor and shall be located at
the point where the conductors receive their supply except for the following:
Branch-Circuit Conductors.
Feeder Taps.
Transformer Secondary Conductors.
Service Conductors.
Busway Taps.
Motor Circuit Taps.
Conductors from Generator Terminals.
Battery Conductors.
Protection systems usually comprise five components:
Current and voltage transformers to step down the high voltages and currents of the
electrical power system to convenient levels for the relays to deal with
Protective relays to sense the fault and initiate a trip, or disconnection, order;
Circuit breakers to open/close the system based on relay and autorecloser commands;
Batteries to provide power in case of power disconnection in the system.
Communication channels to allow analysis of current and voltage at remote terminals of a
line and to allow remote tripping of equipment.
For parts of a distribution system, fuses are capable of both sensing and disconnectingfaults.
Where a branch circuit supplies continuous (runs all the time) loads, or a
combination of continuous and non-continuous (intermittent) loads, the
rating of the overcurrent device shall not be less than the non-continuous
load plus 125% of the continuous load. Branch circuit conductors shall be
protected .. Flexible cords and fixture wires shall be protected in
accordance with Article 240.5.
Communication channels to allow analysis of current and voltage at remote
terminals of a line and to allow remote tripping of equipment.
For parts of a distribution system, fuses are capable of both sensing and disconnectingfaults.
set of conductors feeding a single load, or each set of conductors feeding separate loads,
shall be permitted to be connected to a transformer secondary, without overcurrent
protection at the secondary, as specified in the following conditions:
1.
2.
3.
4.
5.
6.
Protection by Primary Overcurrent Device.
Transformer Secondary Conductors Not over 3 m (10 ft) Long.
Industrial Installation Secondary Conductors Not over 7.5 m (25 ft) Long.
Outside Secondary Conductors.
Secondary Conductors from a Feeder Tapped Transformer.
Secondary Conductors Not over 7.5 m (25 ft) Long.
To protect Overcurrent protection Devices (OCPDs) from physical damage,
overcurrent devices can be installed in enclosures, cabinets, cutout boxes or equipment
assemblies. They can also be installed in panelboards or control boards that are in rooms
or enclosures free from dampness, easily ignitable material and accessible only to
qualified personnel. Also, the operating handle shall be accessible without opening the
door or cover.
Fuses and circuit breakers should be located or shielded so that people will not be
burned or otherwise injured by their operation. Handles or levers of circuit breakers and
similar parts that may move suddenly in such a way that persons in the vicinity are likely
to be injured by being struck by them shall be guarded or isolated.
Outside Taps
of Unlimited
Length.
Where the conductors are located
outdoors of a building or structure,
except at the point of load
termination, and comply with all of
the following conditions:
1- The conductors are protected from
physical damage in an approved
manner.
2- The conductors terminate at a
single circuit breaker or a single set of
fuses that limit the load to the
ampacity of the conductors. This single
overcurrent device shall be permitted
to supply any number of additional
overcurrent devices on its load side.
3- The overcurrent device for the
conductors is an integral part of a
disconnecting means or shall be
located immediately adjacent thereto.
4- The disconnecting means for the
conductors is installed at a readily
accessible location complying with one
of the following:
a. Outside of a building or structure
b. Inside, nearest the point of
entrance of the conductors
c. Where installed in accordance with
230.6, nearest the point of entrance of
the conductors
Load
The current-carrying capacity (In, A) of the breaker should be higher than the
expected load in the circuit. MCCBs are available up to 4000A from Terasaki, but
become less cost-effective for very large ratings (2000A and above). The
advantage of MCCBs for very large ratings is their compact size. An ACB is
physically larger, but more cost-effective for higher ratings.
In a short circuit the contacts of Terasaki MCCBs open before the first peak of the
current waveform (within five milliseconds in a 50 Hz system). The fault current
flowing through the MCCB never reaches its peak, and the fault energy allowed
downstream is limited. This fault limitation protects sensitive equipment which is
not rated to withstand faults. ACBs are selected for their ability to withstand fault
current rather than limit it - (see Discrimination - Selectivity). A typical ACB will
open a short-circuit in between twenty-five and thirty milliseconds, allowing
between one and two cycles of fault current through before opening. The load
protected by an ACB (transformers, busbars for example) should be rated to
withstand fault current for a short duration.
Fault Limitation
In a short circuit the contacts of Terasaki MCCBs open before the first peak of the
current waveform (within five milliseconds in a 50 Hz system). The fault current
flowing through the MCCB never reaches its peak, and the fault energy allowed
downstream is limited. This fault limitation protects sensitive equipment which is
not rated to withstand faults. ACBs are selected for their ability to withstand fault
current rather than limit it - (see Discrimination - Selectivity). A typical ACB will
open a short-circuit in between twenty-five and thirty milliseconds, allowing
between one and two cycles of fault current through before opening. The load
protected by an ACB (transformers, busbars for example) should be rated to
withstand fault current for a short duration.
Fault Level Circuit breakers must be capable of safely interrupting the maximum
potential short-circuit current at their location in the circuit. The circuit breaker
must have a breaking capacity higher than the potential short-circuit current.
Note that the cost of circuit breakers becomes lower with lower breaking
capacity. Potential short-circuit current is determined by: 1. The available power
from the transmission network 2. Transformer characteristics 3. Impedance of
conductors in the distribution system. A fault level study which accounts for
transformer characteristics and conductor impedance at all circuit breaker
installation points will allow selection of breakers with optimum breaking
capacity, saving money. Terasaki's Application Team provide this service.
