Chapter G Study Guide Schneider Electric — Electrical Installation Guide 2018
STUDY GUIDE
Chapter G — Sizing and Protection of
Conductors
Schneider Electric — Electrical Installation Guide 2018
Prepared for self-study — Prescription Engineering reference
TOC \h \o "1-3"HYPERLINK "" \l "_Toc233801671"1. Overview & Methodology......... PAGEREF
_Toc233801671 \h 1
2. Determining the Load Current (IB)............................................................................................ 3
Types of overcurrent.................................................................................................................. 3
3. Conductor Thermal Withstand (Adiabatic Method).................................................................... 3
4. Protective Device Selection Rules (General Conditions).......................................................... 4
By device type............................................................................................................................ 4
Using devices with lower breaking capacity than local fault level.............................................. 4
5. Location of Protective Devices.................................................................................................. 4
Special practical cases.............................................................................................................. 5
Circuits where interruption cannot be tolerated......................................................................... 5
Parallel conductors..................................................................................................................... 5
6. Wiring Systems & Installation Methods (IEC 60364-5-52)........................................................ 5
7. Correction Factors Applied to Iz................................................................................................ 5
8. Busbar Trunking Systems (Busways)........................................................................................ 6
Diversity factor table (typical)..................................................................................................... 6
9. Neutral Conductor & Harmonics................................................................................................ 6
Neutral cross-section rules of thumb......................................................................................... 7
10. Voltage Drop............................................................................................................................ 7
Typical maximum voltage drop (origin to any load point)...........................................................7
Formula (copper, XLPE, per km) — general form..................................................................... 7
Worked examples in the chapter............................................................................................... 8
11. Short-Circuit Current Calculation (Isc)..................................................................................... 8
Basic transformer-based formula............................................................................................... 8
Multiple transformers in parallel................................................................................................. 8
Detailed impedance method...................................................................................................... 8
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Components considered........................................................................................................ 8
Simplified / pre-calculated tables (Chapter F cross-reference method)..................................... 9
12. Verifying the Protective Device Against Short-Circuit..............................................................9
13. Maximum Cable Length for Fault Protection (Phase-Phase / Phase-Neutral)........................ 9
Conventional method assumption.............................................................................................. 9
Correction factor table approach.............................................................................................. 10
14. Electrodynamic (Mechanical) Withstand............................................................................... 10
15. Protective (PE) Conductors................................................................................................... 10
Function & rules....................................................................................................................... 10
PEN conductor (TN-C)............................................................................................................. 10
TN-C-S transition..................................................................................................................... 11
Acceptable materials for PE conductors.................................................................................. 11
Sizing methods for PE (two options)........................................................................................ 11
Equipotential bonding conductors............................................................................................ 11
16. Neutral Conductor — Protection & Switching Rules.............................................................. 11
Overcurrent protection of neutral............................................................................................. 11
Breaking of neutral................................................................................................................... 12
17. Worked Example — Full Installation Study (Section 8)......................................................... 12
Key results (illustrative, from the single-line diagram)............................................................. 12
18. Quick-Reference Formula Sheet........................................................................................... 13
19. Suggested Study / Review Checklist..................................................................................... 13
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Chapter G Study Guide Schneider Electric — Electrical Installation Guide 2018
1. Overview & Methodology
Starting from the origin of the installation, cabling and its protective devices are sized level by
level. At every level the cabling and its protection must simultaneously satisfy two conditions:
• Carry the permanent full load current and normal short-time overcurrents without
damage.
• Avoid voltage drops that degrade load performance (e.g., long motor acceleration times).
The protective device (circuit breaker or fuse) must additionally:
• Protect the cabling/busbars against all overcurrent levels, up to and including short-
circuit currents.
• Ensure protection of persons against indirect contact (fault protection), especially in TN
and IT systems where long circuits reduce fault current and delay tripping.
◦ TT systems are always protected at the origin by an RCD (typically 300 mA).
Design flow: Load current (IB) → cable current-carrying capacity (Iz) → protective device rating
(In) → verify short-circuit withstand → verify voltage drop → verify conductor length limits for
fault protection.
2. Determining the Load Current (IB)
• IB = maximum load current, calculated using diversity factor (ks) and utilization factor
(ku) — see Chapter A, §4.
• Current-carrying capacity Iz = max current the cable can carry indefinitely without
damage.
Iz depends on:
• Cable construction (conductor material, insulation, number of active conductors)
• Ambient temperature
• Method of installation
Types of overcurrent
Type Cause Notes
Too many loads on a healthy circuit Only harmful if sustained beyond the
Overload
(e.g., coincidental motor starts) protective device's time setting
3-phase, 2-phase, or phase-to-neutral
Insulation failure between live
Short-circuit combinations, with or without earth
conductors and/or earth
involvement
3. Conductor Thermal Withstand (Adiabatic Method)
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For short-circuit durations of 5 seconds or less:
I²t = k²S²
• t : duration of short-circuit (seconds)
• S : cross-sectional area (mm²)
• I : short-circuit current (A r.m.s.)
• k : constant depending on conductor/insulation material and initial/final temperature
Consequence: the allowable heat energy is proportional to S² (the square of the cross-sectional
area).
4. Protective Device Selection Rules (General Conditions)
A protective device (CB or fuse) is correctly rated only if all three conditions hold:
1. IB ≤ In ≤ Iz — rated/setting current is between load current and cable capacity (zone “a”)
2. I2 ≤ 1.45 × Iz — conventional tripping/fusing current stays under 145% of cable capacity
(zone “b”)
3. Breaking capacity ≥ Isc at the point of installation — the 3-phase short-circuit breaking
rating exceeds the prospective fault current (zone “c”)
By device type
Circuit breakers: Since precision keeps I2 < 1.45 In automatically, condition 2 is inherently
satisfied.
• Exception: if the CB doesn't protect against overload itself, a separate overcurrent
device must be checked (Sub-clause 5.1 case).
Fuses (type gG): Condition 2 becomes In ≤ Iz / k3, where k3 = 1.31 (larger fuses) or 1.10
(smaller fuses — check exact table values). Fuse breaking capacity ISCF must exceed the 3-
phase Isc at its location.
Using devices with lower breaking capacity than local fault level
Permitted (by IEC and many national standards) only if:
• An upstream device has adequate short-circuit rating, and
• Energy let through by the upstream device is within what the downstream device/cabling
can withstand.
This underlies “cascading” / series rating techniques — using a current-limiting circuit breaker
upstream to reduce the required rating of downstream devices.
5. Location of Protective Devices
• Generally required at the origin of each circuit wherever the permissible current level is
reduced.
May be placed partway along a circuit (segment AB) if:
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• AB is not near combustible material, and
• No socket-outlets/branch connections are taken from AB
Special practical cases
Case Rule
AB installed to practically minimize short-circuit risk (e.g., heavy steel
(1) AB ≤ 3 m
conduit)
(2) Upstream device P1 protects AB against short-circuits
Overload device (S) near the load = start/stop + overload protection; short-
(3) Motor circuits
circuit device (SC) at circuit origin
Circuits where interruption cannot be tolerated
E.g., excitation circuits of rotating machines, large lifting electromagnet circuits, CT secondary
circuits — no circuit interruption is allowed; cable protection becomes secondary.
Parallel conductors
• Must be same c.s.a., length, and material.
• Max permissible current = sum of individual cable ratings.
• Overload/short-circuit protection treated as for a single cable.
• Precautions: mechanical/humidity protection, routing away from combustible materials.
6. Wiring Systems & Installation Methods (IEC 60364-5-52)
Cables/conductors are classified by installation method (letter codes) based on similar current-
carrying characteristics:
Code Description
A1 Insulated conductors/single-core in conduit in a thermally insulated wall
B1 / B2 Conduit on wooden/masonry wall
C Cables clipped direct / on tray
D1 Conduit or ducting buried in ground
E/F Perforated tray (multi-core = E, single-core = F)
G Bare/insulated conductors on insulators
Tables give the base current-carrying capacity (Iz) vs. c.s.a. for each method, insulation type
(PVC, XLPE/EPR), conductor material (Cu/Al), and number of loaded conductors (2 or 3).
7. Correction Factors Applied to Iz
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I’Z = IZ × k1 × k2 × k3 × k4 × (k5)
Cable is selected so that: I’Z ≥ IB
Factor Accounts for Reference condition
k1 Ambient air temperature ≠ 30°C 30°C = 1.0
Ambient ground temperature ≠ 20°C (buried
k2 20°C = 1.0
cables)
Soil thermal resistivity ≠ 2.5 K·m/W (buried 2.5 = 1.0; empirical values also
k3
cables) given by soil nature (wet/damp/dry)
Grouping of multiple circuits/multi-core cables Reduces with more
k4
(bunched, tray, ladder, buried) circuits/proximity
3rd-harmonic content in 4/5-core cables (neutral
k5 See Section 9
heating)
General trend: higher temperatures and more grouped circuits lead to lower correction factors
(below 1), reducing usable cable capacity.
8. Busbar Trunking Systems (Busways)
• Sizing is simpler than cables: no installation-method/insulation/grouping corrections
needed — the manufacturer provides rated current data directly.
• Manufacturer's rated current is based on: rated current, 35°C ambient, 3 loaded
conductors.
• A temperature correction factor (for >35°C) is applied per manufacturer data.
Distribution line current: In = Σ(In of consumers) × ks (diversity factor), plus for industrial
installations, apply a 20% margin: In ≥ IB × ks × 1.2
Diversity factor table (typical)
Number of consumers ks
Lighting, heating 1
2–3 ≈ 0.9
4–5 0.8
10–40 decreasing
>40 0.5
9. Neutral Conductor & Harmonics
• Base cable rating assumes only 3 loaded conductors (no neutral current).
• 3rd-harmonic (and multiples) currents from single-phase non-linear loads add up (don't
cancel) in the neutral — can exceed the phase current.
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3rd harmonic content
Effect Reduction factor k5
h3
0–15% Negligible 1.0
Size based on phase current; reduce cable
15–33% ≈ 0.86
rating
33–45% Size based on neutral current ≈ 0.86
1.0 (no further reduction
>45% Size based on neutral current
needed)
• Maximum theoretical load factor of neutral vs. 3rd harmonic % cannot exceed √3.
• If neutral current > 135% of phase current and sizing is based on neutral current, phase
conductors are under-loaded, so no reduction factor is needed for the phase conductors.
• Special devices (e.g., Compact NSX with OSN tripping unit) allow phase c.s.a. smaller
than neutral c.s.a. for economy.
• Fuse/CB must be sized on the greatest of phase or neutral current.
Neutral cross-section rules of thumb
• Single-phase circuits, or 3-phase circuits with Sph ≤ 16 mm² (Cu) / 25 mm² (Al): Sneutral
= Sphase
• Larger circuits: neutral may be reduced if harmonics are controlled and the neutral is
short-circuit protected — but never below 16 mm² Cu / 25 mm² Al.
• PEN conductor: must never be smaller than 10 mm² (Cu) or 16 mm² (Al), and must
never be open-circuited (combines PE + neutral function).
10. Voltage Drop
Correct load operation requires terminal voltage close to rated value, so voltage drop must be
checked against regulatory limits.
Typical maximum voltage drop (origin to any load point)
Installation type Lighting Other uses
LV supplied directly from public distribution 3% 5%
LV supplied from private MV/LV substation 6% 8%
Caution: The 8% limit is risky for motor loads. At 8% drop under full load, start-up drop can
reach 40% or more, causing stalling/overheating or excessively slow, high-current acceleration.
Recommendation: avoid reaching 8% on voltage-sensitive circuits.
Formula (copper, XLPE, per km) — general form
ΔU = K × IB × L
• K = constant from tables (depends on cable c.s.a., circuit type: single-phase or 3-phase,
power factor)
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• IB = full load current (A)
• L = cable length (km)
Separate formulas exist for phase/phase, phase/neutral, and balanced 3-phase circuits, and
account for resistance R (negligible above 500 mm²) and reactance X (negligible below 50
mm²).
Worked examples in the chapter
• Example 1: 35 mm² 3-phase motor cable — voltage drop checked in normal service and
during start-up (both found acceptable, under 8%).
• Example 2: A distribution line supplying lighting circuits downstream — cumulative
voltage drop (main line + lighting circuit) checked against the 3%/5% limit.
11. Short-Circuit Current Calculation (Isc)
Needed to determine: switchgear breaking capacity, cable thermal withstand, and protective
device settings.
The chapter focuses on the 3-phase “bolted” fault of zero impedance — generally the most
severe and simplest case to calculate.
Basic transformer-based formula
Isc = (In × 100) / Usc
• U20 = no-load secondary phase-to-phase voltage
• In = transformer rated current
• Usc = transformer short-circuit impedance voltage (%)
• Typical Usc: 4% for small/medium transformers, higher for larger units (e.g., 800–3200
kVA range)
Multiple transformers in parallel
Fault current downstream of shared busbars ≈ sum of individual Isc values (a slightly
conservative/high estimate, since busbar/cable impedance between transformers is ignored).
Detailed impedance method
Isc = U20 / (√3 × ZT)
ZT = total impedance of the fault loop up to the fault point = √(RT² + XT²). The network is
divided into sections; resistances are added arithmetically in series, reactances likewise; parallel
sections are combined via reciprocal formulas (R3 = R1·R2/(R1+R2), similarly for X).
Components considered
Element Contribution
Upstream supply network Za (equivalent impedance, often mostly reactive; Ra ≈ 0.1 Xa)
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Element Contribution
Transformer RT and XT (from Usc, load losses Pcu, In)
Circuit breaker Not considered in practice
Busbars Often negligible (resistance small)
R = ρL/S; use cold-state resistivity (20°C) for max Isc, steady-state
Circuit conductors (cables)
(operating temp) for min Isc
Motors (running, contributing Significant only if total motor power > 25% of transformer power:
fault current) Iscm = 3.5 × In per motor (3-phase motors only)
Can reduce fault current by ~20% (not usually credited in basic
Arc resistance at fault point
calcs)
Simplified / pre-calculated tables (Chapter F cross-reference method)
• Given a known upstream Isc and the cable's c.s.a./length, find downstream Isc from
lookup tables.
• Method: select the c.s.a. column → find the nearest length (round down) → descend to
the nearest upstream Isc row (round up) → read downstream Isc at the intersection.
• The same logic applies to aluminium conductors (different table section).
12. Verifying the Protective Device Against Short-Circuit
Two conditions must both be satisfied:
1. Breaking capacity ≥ Isc at the point of installation (3-phase fault current)
2. Elimination time tc for the minimum short-circuit current must be compatible with cable
thermal withstand (valid for tc < 5 s):
tc = (kS / I)²
This is checked graphically: the protective device's tripping/fusing curve must lie below the
cable's thermal-withstand limit curve at all current levels, up to the crossing point.
13. Maximum Cable Length for Fault Protection (Phase-Phase
/ Phase-Neutral)
Beyond a certain circuit length, the minimum short-circuit current (at the remote end) may fall
below the level needed to guarantee instantaneous CB tripping — hence a maximum length
(Lmax) must be respected.
Conventional method assumption
Voltage at the protection point during a fault is assumed to be 0.8 × U (nominal), so:
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0.8 × U = Isc × Zd
For a phase-phase fault (cables ≤ 120 mm², reactance neglected):
Lmax = (0.8 × U × Sph) / (ρ × 2 × Im)
• Im = instantaneous trip current of the CB (use Im × 1.2 for worst-case manufacturing
tolerance)
• Sph = phase conductor c.s.a. (mm²)
• ρ = resistivity, with correction for large c.s.a. due to skin/proximity effect: +15% at 150
mm², +20% at 185 mm², +25% at 240 mm², +30% at 300 mm²
For phase-neutral faults, a similar formula applies, with variants depending on whether Sneutral
= Sphase or Sneutral < Sphase.
Correction factor table approach
Existing Chapter F earth-fault tables can be reused with a correction factor depending on the
Sph/Sneutral ratio (1:1 or 2:1) to get Lmax for phase-phase or phase-neutral faults instead.
14. Electrodynamic (Mechanical) Withstand
• Conductors/busbars must be solidly fixed to withstand electromagnetic forces during a
short-circuit (Icc peak).
• For busways, manufacturers (e.g., Schneider Electric) publish coordination tables
matching specific circuit breaker models/ranges (NG125, NSXm, Compact NSX,
Masterpact, etc.) to specific busway systems — ensuring the combination withstands
short-circuit electrodynamic stress.
15. Protective (PE) Conductors
Function & rules
• Bond all exposed/extraneous conductive parts → main equipotential bonding system;
carry earth-fault current back to the source neutral.
• Must be insulated (green/yellow) and mechanically/chemically protected.
• Must be run close to live conductors in TN/IT schemes (minimizes loop reactance) —
automatic in busways.
• Must NOT include any means of disconnection (switches, removable links).
• Connect exposed conductive parts in parallel, not series — a poor series connection
leaves all downstream equipment unprotected.
• Individual terminal required on common earthing bars.
PEN conductor (TN-C)
• Combines neutral + PE — protective function takes priority; all PE rules apply.
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• Must always connect directly to an appliance's earth terminal, with a looped connection
to the neutral terminal.
• Minimum c.s.a.: 10 mm² Cu / 16 mm² Al; must never be open-circuited.
TN-C-S transition
Once split into separate PE and N conductors (at the PEN terminal/bar), no reconnection of PE
to N is allowed downstream.
Acceptable materials for PE conductors
Supplementary conductor in the same cable/run (recommended), independent conductor (bare
or insulated), metallic busway housing, extruded/mineral-insulated cable sheaths, certain
extraneous conductive elements (with caveats).
Forbidden: conduits, gas pipes, hot-water pipes, and cable-armouring, as PE conductors.
Sizing methods for PE (two options)
Method Basis Typical use
SPE = √(I²t) / k (I = fault current, t = Precise; used for TT
Adiabatic method disconnection time, k = material/insulation and for earthing
constant) conductor sizing
Practical; keeps loop
Sph ≤ 16 mm² → SPE = Sph; 16 < Sph ≤ 35 →
Simplified table method impedance low for
SPE = 16 mm²; Sph > 35 → SPE = Sph/2
TN/IT
Minimum PE c.s.a. when run separately from phase conductors: 2.5 mm² (mechanically
protected) or 4 mm² (not mechanically protected).
Equipotential bonding conductors
• Main bonding conductor: ≥ half the largest PE conductor's c.s.a., capped at 25 mm²
Cu / 35 mm² Al (minimum 6 mm² Cu / 10 mm² Al).
• Supplementary bonding conductor: ≥ half the c.s.a. of the PE conductor it connects to
(or the smaller of two PEs if linking two exposed parts).
16. Neutral Conductor — Protection & Switching Rules
• Color: blue (statutory). PEN: green-yellow with light-blue markings at terminations (or
vice versa).
• Sizing depends on: earthing system (TT/TN/IT), harmonic content, and the indirect-
contact protection method.
Overcurrent protection of neutral
• Generally required, unless: the neutral is protected upstream, OR the circuit is RCD-
protected with sensitivity < 15% of the neutral's admissible current.
• If Sneutral < Sphase → neutral overload and short-circuit protection are required.
• If Sneutral ≥ Sphase → protected inherently by the phase protection device.
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Breaking of neutral
• In a fault, the CB must be omnipolar (opens all poles including neutral simultaneously).
• With fuses, indirect tripping (via an associated switch) is needed, since a blown neutral
fuse alone doesn't achieve this.
• Neutral must never be open-circuited where it also functions as PE (PEN).
• Good practice: every circuit should have isolation means.
17. Worked Example — Full Installation Study (Section 8)
System: 630 kVA transformer (20 kV/400 V, TN-S), with a 250 kVA standby generator and an
isolation transformer feeding a downstream IT sub-system for critical loads. Solved both via
Ecodial software and the manual method in this guide.
Key results (illustrative, from the single-line diagram)
Installation Load
Circuit Cable Length Isc (3-ph)
method current
C1 (Transformer → 2×240 mm² Cu
5m Method F31 518 A 21.5 kA
Main board) (parallel)
21.5 kA
C3 (Feeder) 2×120 mm² Cu 20 m Method 31F 238 A
(upstream)
C7 (Load circuit) 1×95 mm² Cu 5m Method F31 — —
• PE conductor sizing (adiabatic method) for C1: I = 21 kA, k = 143 → gives the
minimum SPE; proposed 1×240 mm² (i.e., the Sph/2 rule for large c.s.a. circuits, since
Sph > 50 mm²).
• Max length check (C3, TN system): the Lmax formula with m = Sph/SPE confirms the
20 m circuit length is fully protected by instantaneous CB tripping.
• Voltage drop check: calculated per circuit (C1, C3, C7) using the K×IB×L method; all
found within acceptable limits.
This example ties together every step in the chapter: IB calculation → cable/Iz selection with
correction factors → protective device rating → short-circuit calculation → thermal withstand
check → max length for fault protection → PE sizing → voltage drop verification.
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18. Quick-Reference Formula Sheet
Purpose Formula
Corrected cable capacity I’Z = Iz · k1 · k2 · k3 · k4 (· k5)
Device rating condition IB ≤ In ≤ Iz
Tripping condition I2 ≤ 1.45 Iz
Fuse sizing condition In ≤ Iz / k3
Adiabatic thermal withstand I²t = k²S²
Transformer Isc Isc = (In × 100) / Usc
Full impedance Isc Isc = U20 / (√3 × ZT)
Iscm = 3.5 × In per motor (if motors > 25% of transformer
Motor fault contribution
power)
Max cable length (phase-phase) Lmax = (0.8 · U · Sph) / (ρ · 2 · Im)
PE conductor (adiabatic) SPE = √(I²t) / k
Voltage drop ΔU = K × IB × L
19. Suggested Study / Review Checklist
☐ Be able to state and apply the 3 protective-device conditions (IB ≤ In ≤ Iz, I2 ≤ 1.45 Iz,
breaking capacity ≥ Isc)
☐ Know the difference between overload and short-circuit, and their respective device
behavior
☐ Be able to identify and apply k1–k5 correction factors from tables
☐ Understand cascading/series rating and when reduced breaking-capacity devices are
permitted
☐ Be able to calculate Isc using both the transformer-only method and the full impedance
method
☐ Know how to check thermal withstand (I²t) graphically and numerically
☐ Be able to calculate Lmax for fault protection on TN systems
☐ Understand PE/PEN conductor sizing rules (adiabatic vs. simplified table)
☐ Understand harmonic effects on neutral sizing (k5, √3 max load factor)
☐ Walk through the full worked example (Section 17) end-to-end without referring to the
text
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