Lead sheathed power control auxiliary cables

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Page

Introduction ................................................................................................................................................................ 1

Customer Service........................................................................................................................................................ 2 - 3

Product Range ............................................................................................................................................................ 4

Specification and Construction .................................................................................................................................. 4 - 5

Ducab Smokemaster Cables .......................................................................................................................... 6

Technical Data ............................................................................................................................................................ 7

Dimensions and Weights:............................................................ Tables 1(A), 1(B), 2, 3 and 4..................... 7 - 10

Current Ratings:...........................................................................Tables 5 to 11 ............................................11 - 15

Rating Factors:.............................................................................Tables 12 to 22 ..........................................16 - 20

Resistance of Conductor, Lead Sheath and Armour:.................. Table 23......................................................21

Short Circuit Ratings - Conductor:............................................. Table 24..................................................... 22

Short Circuit Ratings - Lead Sheath and Armour:...................... Table 25 and 26......................................... 23 - 24

Voltage drop..................................................................................................................................................... 25

XLPE Cable Data for Partial Loads:.......................................... Table 27...................................................... 26 - 27

Contribution by Cable to Earth Fault Loop Impedance:............ Table 28..................................................... 28

Ducab is listed in the following publication issued by the Department of Trade and Industry of the United Kingdom.

“THE DTI QA REGISTER - PRODUCTS AND SERVICES LIST”

Only those companies whose quality system is assessed and certified by U.K. accredited certification bodies appear in theabove publication.

CONTENTS

Ducab Connect

Ducab has a set up Ducab Connect to offer “a one stop package” of Ducab cables and Ducab Connect accessories.Please refer to the tables shown below to identify the correctly sized glands.

Dimensions and Weights:............................................................ Tables 1(A), 1(B), 2, 3 and 4.....................7 - 10

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INTRODUCTION

Due to the wide range of cables in the catalogue, it is advisable, when ordering, to provide as much information aspossible. Please use the following table as a guide:

TECHNICAL ADVISORY SERVICE

The following details will ensure that your enquiries and orders are dealt with quickly and efficiently:

1. Length of cables required and individual drum lengths.*

2. Voltage designation.

3. Relevant British or International Standard.

4. Number of cores.

5. Conductor size and, where applicable, size of reduced neutral conductor.

6. Conductor material i.e. copper, aluminium.

7. Type of insulation.

8. Type of bedding.

9. Type of armour.

10. Type of outer sheath.

11. Any other special requirement, e.g. circular conductors, special PVC sheath material, drum

weight limitation, etc.

* Cables are normally supplied in lengths of 300 metres, 500 metres and 1000 metresdepending on conductor size. Other lengths can be supplied if required.

ORDERING ADVICE

Specialist advice and assistance on all matters concerning Ducab Lead Sheathed Power, Control & Auxiliary Cables isavailable from Ducab Sales Offices or direct from Ducab Head Office,P. O. Box 11529, Dubai, U. A. E., Tel: 971-4-8082500, Fax: 971-4-8082511.E-mail: [email protected] Website: www.ducab.com

Ducab - Dubai Cable Company (Pvt.) Ltd., is the leading manufacturer of electric cables in the Middle East. Established in 1979, the company is owned by the Governments of Dubai and Abu Dhabi. Ducab is based in Jebel Ali, but to meet the continuing demand and keep pace with the steady growth of the region, Ducab completed a second factory in Abu Dhabi in 2005. This state of the art facility doubles the production capacity enabling Ducab to better service its customers.

This catalogue provides working information on Ducab’s complete range of Low Voltage Lead Sheathed Power, Control & Auxiliary Cables rated on to 3.3 kV. Separate catalogues are available for Ducab’s range of Low Voltage Control & Auxiliary Cables, XLPE Power Cables, Ducab Smokemaster - LSF Wires and Cables, Ducab Powerplus Medium Voltage Cables, Ducab Powerplus Medium Voltage Cables for Oil, Gas and Petrochemical Industries and Drum Handling & Installation of Cables.

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Ducab is the premier cable manufacturer in the United Arab Emirates and, since 1979, has been meeting therequirements of customers throughout the Middle and Far East. Ducab’s cables are used by some of the mostdemanding utilities in the world, for the following reasons:

Product QualityDucab is committed to supplying its customers with the highest quality of product and ofservice. Ducab’s Power cables have been type approved by Lloyd’s Register of the UK andhave undergone rigorous type testing by the British Standards Institution (via BASEC) of theUK. They fully conform to BS 6346 and BS 5467 specifications for PVC and XLPE insulatedcables respectively, for electricity supply, up to and including 600/1000 V ratings.

In addition, Ducab was presented with the Dubai Quality Award 1994, for the best localindustrial company of the year. Ducab was honoured with the Dubai Quality Award ’98 GoldCategory. In 2004, Ducab won the DQA Gold category for the second time, the only organisation to achieve suchdistinction. The Gold Award rewards the most distinguished companies which are judged to be world class.

ReliabilitySpecifying the right cable for a particular application is the first step. The key to reliability however, is in themanufacturing process. The cable must be free from material and manufacturing defects, and weaknesses that will berevealed in service.

Ducab constantly monitors its manufacturing processes and operates stringent quality assurance procedures to givelong term reliability. This is of vital significance where cables are to be installed in locations where future accesswould be difficult and this is where Ducab’s reputation and the resources give peace of mind.

PerformanceOptimum cable performance can be provided only by a company such as Ducab, with access to the latestdevelopments in conductor, insulation and protective materials technology. In addition, Ducab’s knowledge ofapplication requirements throughout the Middle and Far East is an assurance of high performance.

Where required, Ducab can incorporate special features, for example to give the cable low smoke and fume (LSF) orreduced flame propagation characteristics, or to resist damage from chafing or impacts.

Our experienced Technical staff can provide guidance on cable selection and installation and can ensure that you getthe right cable for the job.

SafetyDucab is able to maintain a close watch on world developments in cable technology and regulations and therefore ensurethat its products are designed and constructed to be hazard-free under the prescribed conditions of use.

Ducab uses only tried and tested materials and processes in full compliance with all relevantBritish and International Standards. Our cables are therefore manufactured for safe use withoutrisk to health on the understanding that users will exercise the same degree of care in theirselection and application.

Safety is an important issue for Ducab, and the strictest standards are adhered to throughoutthe company. Ducab is proud of its safety record and has been awarded RoSPA (Royal Societyfor the Prevention of Accidents) Gold Awards for safety from 1991 to 1999. From 2000onward, Ducab was awarded the prestigious President’s Award for Health and Safety which isa recognition of Ducab winning 10 consecutive annual Gold awards and acknowledgesDucab’s total commitment to health and safety. In 2002, Ducab was declared the joint winnerof the Manufacturing Industry Sector Award from RoSPA.

Ducab is the first organisation in the Middle East to receive accreditation to OHSAS 18001 by the BASEC (BritishApprovals Service for Cables). Certification to OHSAS 18001 provides a recognisable Occupational Health and SafetyManagement standard against which an organisation’s management systems can be assessed and certified. Based onthe structure of ISO 14001, the standard requires continual improvement in health and safety related activities. andsafety related activities.

CUSTOMER SERVICE

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Quality Management System Certified to ISO 9001Ducab’s Quality Management System conforms to the ISO 9001 International Quality System Standardand was certified by the British Standards Institution. Ducab now holds ISO 9001:2000 certificate issuedindependently by BASEC (British Approval Service for Cables).

Certification to the ISO 9001 International standard demonstrates thatDucab has drawn up written procedures to ensure full compliance with allrequirements of the standard and that these procedures are followed by everydepartment in the company, thus ensuring that the goods leaving Ducab’sfactory are of the highest quality and meet each customer’s requirements inevery respect.

Ducab is particularly proud to have achieved certification to the stringentISO 9001:2000 standard as it is an independent conformation that it designs, manufactures and tests cablesconsistently to accepted standards. ISO 9001 is widely used throughout Europe, and is therefore areassurance to Ducab’s customers that the products and service supplied by the company are equal to thebest in the world.

Environmental Management System Certified to ISO 14001Ducab’s Environmental Management System conforms to the ISO 14001 International EnvironmentalManagement Standard and is certified by BASEC.

Certification to the ISO 14001 International standard shows that Ducab hasa well defined structure and established working practices aimed at limitingits impact on the environment. Measurement and monitoring of effects,issuing work instructions, training of personnel and taking correctiveactions are all essential elements to limiting the impact on the environment.Ducab has set improvement targets to reduce the significant environmentalimpacts associated with its activities.

Ducab is proud to be the first cable manufacturer in the region to achieve certification to ISO 14001 andthis certification along with its quality, business success and safety record demonstrates that Ducab is aworld class organisation and can hold its head up to any business community throughout the world.

Ducab ShareekDucab’s customer care programme is designed to ensure that customers receive a consistently high level ofservice from Ducab’s dedicated staff.

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PRODUCT RANGEThe XLPE insulated, lead sheathed cables detailed in this publication are rated at 600/1000V; 1900/3300V rated cablesare also included. The cables comply to IEC 60502 - 1 (XLPE) and BS 5467 (XLPE) specifications and EEMUApublication No. 133. Cables can also be supplied to the National Standards of other countries, details are available uponrequest. All of the cables in this publication meet the requirements of IEC: 332 Part 1 'Test on electric cables under fireconditions' and BS 4066 Part 1.

The cables detailed in this brochure are designed to facilitate land-based activities in the oil, gas, petroleum andchemical industries where the spillage or seepage of corrosive liquids and vapours pose a threat to circuit integrity.Contaminants such as petroleum-based substances are capable of permeating cable sheaths and passing along andbetween armour wires, thus the inevitable degradation of insulating materials may not be limited to the proximity ofpenetration.

To counter the hazard, cables are constructed with an impermeable lead or lead alloy sheath around the core assembly.This lead sheath and its subsequent coverings of PVC bedding, galvanised steel wire armour and outer PVC sheath arethe essence of the Engineering Equipment and Materials Users Association (EEMUA) "Specification of UndergroundArmoured Cables Protected Against Solvent Penetration and Corrosive Attack," Publication No. 133. The purpose ofthis specification is to establish the degree and manner of protection to be applied over the insulated core assembly ofalmost any cable such that it is graded suitable for use by the industries concerned in those installation locations withthe potential contamination hazards. Please see inside front cover for cable construction.

Note: Dimensions and Performance data for 31/2 core cables (not included here) can be furnished on request.

SPECIFICATION AND CONSTRUCTION

Lead Sheathed P o wer Cable

Lead Sheathed Auxiliary Cable 6 5 4 3 2 1

6 5 4 3 2 1

Construction 1 - Plain Copper Conductor

2 - Insulation XLPE or PVC

3 - Lead Sheath

4 - PVC Bedding

5 - Galvanised Steel Wire Armour

6 - PVC Oversheath

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CONDUCTORSThe conductors used in Ducab's lead sheathed power, control and auxiliary cables are aluminium or high conductivityannealed copper which meet the requirements of BS 6360 "Conductors in insulated cables and cords" and IEC 60228.Where possible, stranded conductors are shaped and compacted to reduce dimensions and give a smoother profile. Thiscompacting sometimes entails a change in the number and size of wires, therefore compacted conductors are designatedby nominal cross sectional area rather than by stranding configuration.

The material of insulation is Cross Linked Polyethylene (XLPE). As an insulation material, XLPE has severaladvantages over PVC, although it is not flame retardant. The good qualities of polyethylene are retained but at hightemperatures the toughness and physical properties are improved. In particular there is greatly enhanced resistance todeformation.

Having superior thermal and mechanical properties compared with PVC, XLPE also has higher insulation resistance,enabling its thickness to be reduced, leading to a corresponding reduction in the overall diameter and weight of afinished cable.

Core identification is as follows unless otherwise specified:

Number of cor es Identif icationSingle (Power) Red or BlackTwo (Power/Control) Red, BlackThree (Power/Control) Red, Yellow, BlueFour (Power/Control) Red, Yellow, Blue, BlackFive (Power) Red, Yellow, Blue, Black, Green/YellowFive or more (Auxiliary) White cores with number printing in black

Black denotes the neutral and the other colours the phase conductors. Other non-stranded core colours can beconsidered.

Non-hygroscopic polypropylene fillers are included between laid-up cores where necessary.

A separator tape of non-hygroscopic polypropylene material is applied over XLPE cores.

A PVC bedding under the lead sheath, while not standard, may be included on request.

This protects the core assembly against moisture, hydrocarbons and corrosive contaminants found below ground, andmeets the requirements of BS 801 and EEMUA 133 specifications.

Lead alloy E possesses characteristics as a sheathing material important both in manufacture and installation. For cablesburied in the ground the excellent corrosion-resistant properties are particularly important.

The thickness of the lead sheath will comply with EEMUA - 133 for cables to IEC 60502 - 1/ BS 5467 , unlessotherwise specified.

A layer of extruded PVC is incorporated into the design to separate the lead sheath from, and provide a sound beddingfor, the metallic armour.

This guards against mechanical damage to the cable and comprises a single layer of spirally applied galvanised steelwires for all multicore cables. Copper wires may be included as necessary to increase the conductivity. Aluminium wireis used in armouring single core cables.

FILLERS

LEAD SHEATH

BEDDING

ARMOUR

INSULATION

CORE IDENTIFICATION

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Ducab Smokemaster LSF CABLESDucab can manufacture a dedicated cable called Ducab Smokemaster LSF (Low Smoke and Fume) forinstallations where fire and its associated problems - the emission of smoke and toxic fumes - offer a serious potentialthreat. Ducab Smokemaster LSF compound is free from halogens (fluorine, chlorine and bromine) and whentested to BS 6425 Part 1 and IEC 754 Part 1 the acidic gas evolved during combustion is less than 0.5% by weight ofmaterial. Furthermore, when tested in accordance with BS 2782 Method 141D, the oxygen index of both bedding andsheath will not be less than 30. These cables comply with BS 6724.

Ducab Smokemaster LSF Cable:• is slow to ignite, burns slowly and gives off reduced smoke and fumes which can kill people• does not produce corrosive halogen acid gases which destroy sensitive electronic equipment• helps people to escape from a fire - helps them to see and to breathe for longer• wins time for people to escape and for emergency services to help• is essential in public buildings, transport or confined areas where larger numbers of people-

many of them strangers to the surroundings or infirm - regularly congregate

Ducab Smokemaster LSF cables should be used in any location where the outbreak of fire would constitute animmediate threat to life and to the performance of sensitive electronic equipment.

Note: For technical data for Ducab Smokemaster LSF cables, please refer to Ducab Smokemastercatalogue.

INSTALLATION GUIDEEnvironmentAll cables in this catalogue can be installed and operated indoors, outdoors or underground.

Minimum bending radiusThe installation radius for any cable should be as great as possible. For all cables listed in this catalogue, it should notbe less than twelve times the overall cable diameter.

Note: For technical detail on Installation guide, please refer to Ducab Drum Handling & Installation Catalogue.

Following types of materials may be specified for oversheathing.• General Purpose: Extruded PVC Type 9 Compound as per BS 7655. • Medium Density Polythylene (MDPE): Offers higher protection from water ingress and mechanical abrasion. • Anti - Termite: Termite resistance can be built in both types described above by compounding with proper additives.• Reduced Propagation (RP): Retards propagation of flame in fire situation. (Oxygen Index = 30)• Reduced Propagation and Lo w Acid Fumes (RPLHCL): Retards propagation of flames and gives low emission

of hydrochloric acid fumes. (OI = 30 & acid gas emission is less than 18%)• Ducab Smokemaster Low Smoke & Fume (LSF): Ducab Smokemaster cables are ideal forinstallation where the dense black smoke generated by cables with PVC outer sheath in a fire are a danger to people.Ducab Smokemaster is characterised by the features as Oxygen Index greater than 35, acid-gas liberation almostnil (< 0.5%) and smoke density within controllable limit of 40 % smoke density. Ducab Smokemaster cablesare offered to BS 6724.

OVERSHEATH - FINISH

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DIMENSIONS AND WEIGHTS XLPE INSULATED LEAD SHEATHED COPPER/ALUMINIUMCONDUCTOR POWER & CONTROL CABLES TO IEC 60502-1600/1000V Table 1(A)

Nominal Approximate diameter Approximate 416AA-•

area of Over Armour Overall Cable Cable 416AB-( )•

conductor lead wire cable weight weight 475AA-• 424PB•

Copper Aluminiummm2 mm mm mm kg/km kg/km

507095

120150185240300400500630800

1000

12.714.516.318.119.922.325.127.631.136.340.346.350.1

1.61.61.61.61.61.62.02.02.02.52.52.52.5

21.523.325.126.928.731.335.338.042.148.753.159.563.9

1308162020202372273033384271502962628093

100001273615384

1013119014311629181821952767314338655035601475979018

53T (93T)54T (94T)54T (94T)55T (95T)56T (96T)56T (96T)

57T57T58T60T62T64T65T

55T55T55T56T56T56T57T57T59T59T61T61T61T52535353555556565656575759595961

51 (91)52 (92) 52 (92)52 (92)53 (93)54 (94)55 (95)56 (96)55 (95)56 (96)

575758606162

51 (91)52 (92)52 (92)53 (93)54 (94)54 (94)56 (96) 56(96)

575758596062646668

5253535555555656575759595961616363

52 (92)52 (92)53 (93)53 (93)54 (94)55 (95)56 (96)

57575860606264666870

5353555555565657575959596161636364

SINGLE

CORE

1.52.546

10162535

D507095

120150185240300

8.09.2

10.611.713.615.518.921.519.022.124.027.230.333.738.942.9

0.91.251.251.251.251.61.61.61.62.02.02.02.52.52.53.15

15.417.318.719.821.724.327.730.528.232.534.838.442.946.952.758.0

667830970

109813211705224227402651328643265217650077759776

12195

------

1927230020732456317637694728554768488517

TWO

CORE

1.52.546

1016253550+7095

120150185240300400

8.49.8

11.212.514.216.520.322.923.826.129.933.437.442.346.852.257.8

0.91.251.251.251.251.61.61.62.02.02.02.52.52.52.52.53.15

15.817.919.320.622.325.329.131.934.236.940.946.050.455.961.067.074.7

707899

10451203144519402610320038464770599575568970

11005134451613020620

------

214025402980352542705385631576659055

1061013570

THREE

CORE

1.52.546

101625+35507095

120150185240300400

9.210.712.413.716.018.220.423.426.330.234.437.942.447.653.058.766.1

1.251.251.251.251.61.61.61.62.02.02.52.52.52.52.53.153.15

17.318.820.521.824.827.029.432.836.941.247.050.956.061.867.875.684.0

846932

1116129617552285284035504630594578609350

1130013630169302119026180

------

22002670342042455495638276509056109131361716539

FOUR

CORE

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area of Over Armour Overall Cable 416AB-( )•

conductor lead wire cable weight 475AA-• 424PB•

mm2 mm mm mm kg/km

DIMENSIONS AND WEIGHTSXLPE INSULATED LEAD SHEATHED COPPER/ALUMINIUM

CONDUCTOR AUXILIARY CABLES TO IEC 60502-1

Nominalarea of

conductor

2.5mm2

12.716.116.719.823.524.127.231.7

1.251.601.601.601.601.602.002.00

20.824.925.528.632.533.337.642.5

12421730183623552900306039624980

53 (93)54 (94)54 (94) 56 (96)

57575759

5555555657575759

No.of

cores

710121924273748

Nominalarea of

conductor

4.0 mm2

14.619.623.228.132.036.2

1.251.601.602.002.002.00

22.328.432.238.342.847.2

54 (94)56 (96)56 (96)

575960

555656575959

135021322735378547705700

No.of

cores

71219273748

Explanatory Notes:1. Lead sheathed thickness of all cables will conform to recommendations of EEMUA - 1332. Tolerance on the above dimensions are -0.5mm and +0.5mm.3. The minimum diameter of aluminium wire armour for single core cables is 1.6mm.4. Cable sizes marked + and higher have sector shaped conductors.5. Cable sizes marked ‘D’and higher have ‘D’shaped conductors.

600/1000V Table 1(B)

1.52.546

10162535

10.811.613.414.917.619.824.827.8

1.251.251.251.251.601.601.602.00

18.919.721.123.026.428.634.038.2

9821102121015502150261036904740

52 (92)52 (92)53 (93)54 (94)55 (95)56 (96)

5757

5353555556565757

FIVE

CORE

Nominalarea of

conductor

1.5mm2

11.714.915.318.121.322.024.928.7

1.251.251.251.601.601.601.602.00

19.823.023.426.930.130.833.939.1

10851400145020002380256030934065

52 (92)54 (94)54 (94)55 (95)56 (96)56 (96)

5757

5355555656565757

No.of

cores

710121924273748

• 416AA - series - RTL for Lead sheath cable (industrial)• 416AB - series - RTL E.Exe increased safety Gland• 475AA - series - RTLF E.Exd flameproof Gland• 424PB - series - BARR.PB E.Exd Explosion Proof Barrier Gland

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DIMENSIONS AND WEIGHTSXLPE INSULATED LEAD SHEATHED POWER AND

CONTROL CABLES TO BS 5467 AND EEMUA 133600/1000V

* Cable with 1.6mm wire armour, a deviation from BS 5467.Tolerance on the above dimensions are -0.3mm and +0.5mm. Cable sizes marked + and higher have sector shaped conductors.

Table 2


area of Over Armour Overall Cable Cable 416AB-( )•

conductor lead wire cable weight weight 475AA-• 424PB•

Copper Aluminiummm2 mm mm mm kg/km kg/km

50*70*95*

120*150185240300400500630800

1000

13.015.016.818.520.522.825.528.132.337.040.847.552.5

1.61.61.61.61.61.61.61.62.02.02.02.52.5

20.822.624.526.228.530.833.536.441.846.650.859.264.2

13001620204023802840336541805060640080009720

1270015400

1005119014511621192822222676317440034942573475619034

53T (93T)54T (94T)54T (94T)55T (95T)56T (96T)56T (96T)

57T57T59T60T62T64T66T

55T55T55T56T56T56T57T57T59T59T61T61T63T

SINGLE

CORE

1.52.546

1016253550+7095

8.69.5

10.811.613.715.518.921.319.022.224.8

0.90.90.90.90.91.251.251.61.61.62.0

14.015.016.517.519.821.825.529.427.230.534.5

640730840960

1180154020602670264034004530

------

17452230206225703380

51 (91)51 (91)52 (92)52 (92)53 (93)54 (94)55 (95)56 (96)56 (96)56 (96)

57

5252535355555656565657

TWO

CORE

1.52.546

1016253550+7095

120150185240300

9.210.411.413.014.816.520.523.024.026.530.533.537.842.848.252.2

0.90.90.90.91.251.251.61.61.61.62.02.02.52.52.52.5

14.516.017.018.521.523.028.631.232.035.040.543.549.454.560.265.2

700815920

1080150017502650322036304560611073008980

108701350016150

------

218025602764331543855129632575309110

10630

51 (91)52 (92)52 (92)53 (93)54 (94)54 (94)56 (96)56 (96)

5757585960626466

52535355555556565757595959616163

THREE

CORE

1.52.546

101625+35507095

120150185240

10.111.112.813.816.518.820.523.226.230.534.837.843.247.853.8

0.90.90.91.251.251.251.61.61.62.02.02.52.52.52.5

15.616.818.520.322.825.528.531.334.640.544.849.855.060.066.5

765870

1030133016702120280034304260585073409400

112801360017000

------

21602550305041504975643276309020

10980

52 (92)52 (92)53 (93)53 (83)54 (94)55 (95)56 (96)56 (96)

57586060626466

535355555556565657595959616163

FOUR

CORE

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Approximate diameter 416AA-•

No. of Cores Over Lead Armour wire Overall cable Approx. weight 416AB-( )• 424PB-•

mm mm mm kg/km 475AA-•

DIMENSIONS AND WEIGHTSLEAD SHEATHED XLPE INSULATED CABLES

TO BS 5467 & EEMUA 133600/1000V

57

1012192427323748

10.011.213.614.216.619.420.121.522.626.3

0.90.91.251.251.251.61.61.61.61.6

16.217.520.721.323.928.028.730.131.235.1

780875

12301265162021222553256727323355

52 (92)52 (92)53 (93)54 (94)54 (94)55 (95)56 (96)56 (96)56 (96)

57

53535555555656565657

57

1012192427323748

11.612.616.016.820.023.424.226.027.231.7

0.90.91.251.251.61.61.61.61.62.0

17.818.823.424.028.531.832.435.036.042.1

953108014601600231828103064340036564908

52 (92)53 (93)54 (94)54 (94)56 (96)

5757575759

53555555565757575759

Nominal area of conductor 2.5 mm2

Nominal area of conductor 4.0 mm 2

57

10121924273748

12.914.118.318.922.526.627.330.835.8

0.91.251.61.61.61.61.62.02.0

19.321.226.727.331.134.636.341.246.4

114013702070220529903590377549906125

53 (93)54 (94)55 (95)55 (95)56 (96)

57575860

555556565657575959

Approximate diameter 416AA-•

Nominal Area of Over Lead Armour wire Overall cable Approx. weight 416AB-( )• 424PB-•

Conductor mm2 mm mm mm kg/km 475AA-•

C0PPER CONDUCTOR XLPE INSULATED LEAD SHEATHED 3CORE CABLES TO BS 5467 & EEMUA 133

162535

50+7095

120150185240300

22.525.027.526.031.035.237.041.244.049.453.0

1.61.61.62.02.02.02.52.52.52.52.5

31.033.536.036.041.045.549.053.256.062.266.0

26403230377543605500690084509800

113501400016350

56 (96)57575758606062636466

5657575759595961616163

1. Cable marked + and higher have sector shaped conductors2. Tolerance on the above dimensions are -0.3mm and +0.5mm

Table 3

1900/3300V Table 4

Nominal area of conductor 1.5 mm 2

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Current ratings for XLPE insulated cables for 'ground' and 'duct' installation are derived from the latest issue of ERAReport 69-30 Part 5 which is based upon IEC Publication 287. The ratings for 'In Air' installation are taken from IEEWiring Regulations, 16th Edition.

All the ratings (refer tables 5 to 11) given are for single circuits installed thermally independent of other circuits or anyother heat source and the basis of the standard conditions of installation given under the head 'Rating Factors'. For otherambient or ground temperatures, depth of laying, soil thermal resistivity, the rating must be multiplied by relevant ratingfactors in tables 12 to 22.

It should be noted that if XLPE insulated cables, are subjected to operating temperatures appreciably higher than the90˚C permissible for continuous operation, the insulation will undergo premature ageing thus affecting the normal lifeof the cable. However, limiting maximum conductor temperature to 105˚C during overloads with duration not exceeding4 hours on any one occasion, or a maximum of 100 hours in any 12 consecutive months, or a total of 500 hours in thecable's lifetime, would be tenable.

IEE Wiring Regulations 16th edition - requirement for cables

The IEE Wiring Regulations for installation and selection of cables cannot be approached in isolation from the otherequipment in the installation. In particular the devices providing protection against overload, short circuit, shock byindirect contact and over-heating of protective conductors during an earth fault, affect the selection of cables.

For guidance and assistance, given below are some of the IEE Wiring Regulation's requirements for cables:

Protection against overload current: (Clause 433-01-01 of the 16th Edition of theIEE Wiring Regulations)

This states the requirements, which effectively determine the sustained current ratios of the cable viz.:

i) The current rating of the cable should not be less than the nominal current or current setting of the device providingprotection against overload, which in turn should not be less than the circuit current. ii) The overload protection should operate at not more than 1.45 times the current rating of the cable.

The second requirement (ii) is met if the first (i) is met when the protective device is any of the standard fuses or MCB'smentioned in the regulations, except rewirable types of fuse to BS 3036.

With fuses to BS 3036, the current ratings of the cable should not be less than 1.38 times the fuse rating to satisfy (ii).

Protection against short circuit: (Clause 434 of the 16th Edition of the IEEWiring Regulations)

The cable has to have adequate short-circuit capacity for the current let through by the device providing short circuitprotection for the time it will flow.

The formula in Section 434-03-03 is effectively that used by cable makers to give the short-circuit ratings in theirpublications.

If the device providing protection against short circuit is the same as that providing protection against overload, andtherefore, has a rating not higher than the rating of the cables, the short circuit capacity of the cable will automaticallybe adequate, there is no need to check.

CURRENT RATINGS

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Protection against indirect contact by interruption of supply: (Clause 412 of the16th Edition of IEE Wiring Regulations)

Protection against shock due to contact with exposed conductive parts of equipment during a fault to earth is deemed tobe provided if disconnection due to flow of the fault current through the protective device will occur, either

within 0.4 seconds for final circuits supplying socket outlets. (Table 41A of the 16th Edition of the IEE WiringRegulations)

or

within 5 seconds for final circuits supplying fixed equipment. (Clause 413-02-12 of the 16th Edition of the IEE WiringRegulations)

Regulation 413 gives values of earth fault loop impedances, which satisfy these conditions when the standard types ofprotective devices are used.

Cables make the major contribution to earth fault loop impedance, but the impedance of the supply external to theinstallation has to be taken into account.

It is not possible to say what maximum length of standard cables may be used in the installation without exceeding therequirements for earth fault loop impedance in the absence of information on the external impedance for the particularinstallation.

Table 28 give estimated values of the contribution to earth loop impedance by XLPE insulated copper conductor, steelwire armoured cables to BS 5467.

Cross sectional areas of protective conductors: (Clause 543 of the 16th Edition ofIEE Wiring Regulations)

Regulation 543 explains how the cross sectional area of the circuit protective conductor should be calculated to avoid itover-heating during a fault to earth. Again, the area required depends on the characteristics of the device providingprotection under short circuit.

The steel wire armour of standard cables to BS 5467 (XLPE) provides the required area, or more, when the protectivedevice is one of the standard fuses or MCB's with a rating not higher than the current rating of the cable (assumingdisconnection within 5 seconds).

For the most of the cables the armour is still adequate when the fuse rating is one or two steps, or even more, above thecurrent rating of the cable, the margins being greater for the small sizes and 4 core cables than for the larger sizes andtwo core cables.

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CURRENT RATINGS (ac)

LEAD SHEATHED SINGLE CORE POWER CABLES600/1000V Table 5

Stranded Aluminium Conductors

507095

120150185240300400500630800

1000

235290345390435490560630700770840888942

235280330370405440500550580620670692735

222285346402463529625720815918

102711191214

0.870.620.470.390.330.280.240.210.200.180.170.170.16

0.930.700.560.480.430.390.350.320.300.280.260.250.24

0.870.620.470.390.330.280.240.210.200.180.170.170.16

175220260295330375435490540580630

180220260295330365410455480510540

162207252292337391465540625714801

1.400.980.720.580.480.390.310.270.350.310.28

1.601.000.790.660.570.490.420.380.380.350.32

1.400.980.740.600.490.410.340.290.250.220.20

Stranded Copper Conductors

Nominalarea of

conductormm2

Direct ingroundamps

In singleway ducts

amps

Installedin airamps

Ground

mV

Duct

mV

Air

mV

Direct ingroundamps

In singleway ducts

ampsInstalled

in airamps

Ground

mV

Duct

mV

Air

mV

Current Ratings Current RatingsApproximate voltage drop perampere per metre

Approximate voltage drop perampere per metre

3D 3D

LEAD SHEATHED 2 CORE POWER CABLES600/1000V Table 6


16*25*35*507095

120150185240300

140180215255315381410472539636732

115145175210260313344384432504560

115152188228291354430480540630700

2.91.91.31.00.70.50.40.40.30.20.2

2.91.91.31.00.70.50.40.40.30.20.2

2.91.91.31.00.70.50.40.40.30.20.2

135165195240288

110130155195237

112138166211254

3.12.21.71.10.8

3.12.21.71.10.8

3.12.21.71.10.8


Nominalarea of

conductormm2

Direct ingroundamps

In singleway ducts

amps

Installedin airamps

Ground

mV

Duct

mV

Air

mV

Direct ingroundamps

In singleway ducts

amps

Installedin airamps

Ground

mV

Duct

mV

Air

mV



* Circular conductors, all others are sector shaped

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16*25*35*507095

120150185240300400

115150180215265315360405460530590667

94125150175215260300335380440495570

99131162197251304353406463546628728

2.51.71.20.90.60.50.40.30.30.20.20.2

2.51.71.20.90.60.50.40.30.30.20.20.2

2.51.71.20.90.60.50.40.30.30.20.20.2

89115135165200240275310350410460520

7298

120145185224264305350418488562

7498

120145185224264305350418488562

4.22.71.91.41.00.70.60.50.40.30.30.2

4.22.71.91.41.00.70.60.50.40.30.30.2

4.22.71.91.41.00.70.60.50.40.30.30.2


Nominalarea of

conductormm2

Direct ingroundamps

In singleway ducts

amps

Installedin airamps

Ground

mV

Duct

mV

Air

mV

Direct ingroundamps

In singleway ducts

amps

Installedin airamps

Ground

mV

Duct

mV

Air

mV





16*2535507095

120150185240300400

115150180215265315360405460530590667

94125150175215260300335380440495570

99131162197251304353406463546628728

2.51.71.20.90.60.50.40.30.30.20.20.2

2.51.71.20.90.60.50.40.30.30.20.20.2

2.51.71.20.90.60.50.40.30.30.20.20.2

89115135165200240275310350410460520

7294

110135165200230255295340385443

7498

120145185224264305350418488562

4.22.71.91.41.00.70.60.50.40.30.30.2

4.22.71.91.41.00.70.60.50.40.30.30.2

4.22.71.91.41.00.70.60.50.40.30.30.2


Nominalarea of

conductormm2

Direct ingroundamps

In singleway ducts

amps

Installedin airamps

Ground

mV

Duct

mV

Air

mV

Direct ingroundamps

In singleway ducts

amps

Installedin airamps

Ground

mV

Duct

mV

Air

mV





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Current Ratings (amps)Nominalarea of in in in

conductor Air Duct Ground

mm2


3 CORE LEAD SHEATHED POWER CABLES1900/3300V Table 9

162535

507095

120150185

240300

106142168

202255312

361410471

554634

96124147

174214257

293328371

428480

114147175

207254304

345387436

502563

Nominal Two core Three and Four corearea of Current Volt drop per Current Volt drop per

conductor rating amp per rating amp permetre metre

mm2 amp mV amp mV

1.5 29 31 25 272.5 39 19 33 164 52 12 44 106 66 7.9 56 6.8

10 90 4.7 78 4.0

LEAD SHEATHED CONTROL CABLES600/1000V Table 10

Installed in free air (Reference Method 11 on cable tray orMethod 13 in free air, IEE Wiring Regulations, 16th Edition)

Nominal Two core Three and Four corearea of Current rating Volt drop Current rating Volt drop

conductor In In duct per amp In In duct per ampground per metre ground per metre

mm2 amp amp mV amp amp mV

Table 11Laid directly in ground, run in single-way ducts

Ratings based on Ambient air temp 30˚C

1.52.546

10

38496581

109

3141536789

3119127.94.7

3242556992

2634455675

2716106.84.0

Ratings based on Ground temp 15˚C, Soil thermal resistivity 1.2˚C m/WDepth of laying 0.5m. All circuits thermally independent. 100 mm diameter single-way ducts.

Current Ratings for cables having more than four cores are available on request.

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RATING FACTORS

RATING FACTORS FOR GROUND TEMPERATURE

RATING FACTORS FOR VARIATION IN THERMAL RESISTIVITY OF SOIL (AVERAGE VALUES)

CABLES LAID DIRECTLY IN GROUND

The maximum sustained ac current ratings given in this section are based, where applicable, on ERA Report 69-30:

Part V - sustained current ratings for armoured cables with thermosetting insulation to BS 5467.

Any other current rating will have been calculated using agreed formulae and methods from IEC 287.

Defined conditions of installationAmbient air temperature: 30˚CGround thermal resistivity: 1.2Km/WGround temperature: 15˚CDepth of laying:

600/1000V cables 0.5m1.9/ 3.3kV cables 0.8m

Maximum conductor operating temperature: 90˚C

Table 12

Table 13

Ground temperature 15˚C 20˚C 25˚C 30˚C 35˚C 40˚C 45˚C

Rating Factor 1.0 0.97 0.93 0.89 0.86 0.82 0.76

Size of cablesmm2

Single core cablesUp to 150From 185 to 300From 400 to 1000

Multicore cablesUp to 16From 25 to 150From 185 to 300

1.161.171.17

1.121.121.12

1.071.071.07

0.910.910.91

0.810.800.80

0.730.730.73

0.660.660.66

1.121.141.15

1.081.101.10

1.051.061.07

0.930.920.92

0.840.820.81

0.770.750.74

0.720.690.67

Soil thermal resistivity in Km/W

0.8 0.9 1.0 1.5 2.0 2.5 3.0

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RATING FACTORS FOR DEPTH OF LAYING(TO CENTRE OF CABLE OR TREFOIL GROUP OF CABLES)

GROUP RATING FACTORS FOR CIRCUITS OF THREE SINGLE CORE CABLES IN TREFOIL OR LAID FLAT TOUCHING, IN HORIZONTAL FORMATION

Table 14

Table 15

Depth of laying

metres

0.500.600.801.001.251.501.752.002.503.00

or more

1.000.990.970.950.940.930.920.910.900.89

1.000.980.960.930.920.900.890.880.870.85

1.000.970.940.920.890.870.860.850.840.82

--

1.000.980.960.950.940.920.910.90

--

1.000.970.950.930.910.890.880.86

Up to 50mm2

600/1000 Volt 1900/3300 Volt

70mm2

to 300mm2 Above 300mm2 Up to300mm2 Above 300mm2

Number of Circuits

600/1000Volt cables

1900/3300Volt cables

23456

0.780.660.610.560.53

0.780.660.590.550.52

0.800.680.620.580.55

0.820.710.650.610.58

0.860.770.720.680.66

0.890.800.770.740.72

0.910.830.800.780.76

0.810.700.640.600.57

0.830.730.680.640.61

0.880.790.730.730.71

0.910.840.810.790.78

0.930.870.850.850.82

23456

Spacing of Circuits

Touching

Trefoil Laid flat 0.15 m* 0.30 m 0.45 m 0.60 m

* This spacing will not be possible for some of the larger diameter cables.

SPACING SPACING

In ERA Report 69-30 Part V, the types of load are classified under three headings, viz:

Type A Cables carrying a constant load throughout the year.Type B Cables carrying varying loads, maximum in summer period.Type C Cables carrying varying loads, maximum in winter period.

With knowledge of the type of load to be imposed on the cable it is then possible to determine the soil thermal resistivity along thecable route in accordance with recommendations in ERA Report 69-30.

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GROUP RATING FACTORS FOR MULTICORE CABLES IN HORIZONTAL FORMATION

RECOMMENDED DUCT DIMENSIONS AND CABLE SIZES

Table 16

Table 17

Number of Cables in Group

Overall cable diameter

mm

Up to and including 65

Above 65 up to and including 90

100

125

130

160

Inside diametermm

Outside diametermm

Spacing

Duct

Touching 0.15 m 0.30 m 0.45 m 0.60 m

600/1000volt cables

1900/3300volt cables

23456

23456

0.810.700.630.590.55

0.800.680.620.570.54

0.850.760.710.660.64

0.890.810.770.730.71

0.910.840.810.780.77

0.930.870.840.820.81

0.870.780.740.700.68

0.910.840.810.780.77

0.930.880.860.840.83

0.950.900.890.870.87

SPACING

CABLES INSTALLED IN DUCTSThe term ducts applies to single way earthenware, fibre or ferrous pipes.

Rating factors for ground temperature

Note: Same as for direct in ground, refer to Table 12.

RATING FACTORS OF VARIATION IN THERMAL RESISTIVITY OF SOIL(AVERAGEVALUES) Table 18

Size of cablemm2

Single Core CableUp to 150From 185 to 300From 400 to 1000

Multicore CablesUp to 16From 25 to 150From 185 to 500

Soil thermal resistivity in Km/W

0.8

1.101.111.12

1.041.061.07

1.071.081.08

1.031.041.05

1.041.051.05

1.021.031.03

0.940.930.93

0.970.950.95

0.860.850.84

0.920.900.88

0.800.790.78

0.880.850.83

0.760.750.74

0.860.810.78

0.9 1.0 1.5 2.0 2.5 3.0

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RATING FACTORS FOR DEPTH OF LAYING (TO CENTRE OF DUCT OR TREFOIL GROUP OF DUCTS) Table 19

Depth of laying

m

0.500.600.801.001.251.501.752.002.503.00

or more

1.000.980.950.930.910.890.880.870.860.85

1.000.990.980.960.950.940.940.930.920.91

--

1.000.980.950.930.920.900.890.88

--

1.000.990.970.960.950.940.930.92

600/1000 Volt 1900/3300 Volt

Single Core Multicore Single Core Multicore

GROUP RATING FACTORS FOR SINGLE CORE CABLES IN TREFOILSINGLE WAY DUCTS, HORIZONTAL FORMATION (AVERAGE VALUES) Table 20

Number of Circuits

600/1000Volt Cables

1900/3300Volt Cables

23456

0.870.780.740.700.69

0.850.750.700.670.64

0.880.800.770.740.72

0.900.830.800.780.76

0.910.840.810.790.78

0.930.870.850.830.82

23456

SpacingTouching 0.45 m 0.60 m

SPACING

GROUP RATING FACTORS FOR MULTICORE CABLES IN SINGLE WAYDUCTS, HORIZONTAL FORMATION (AVERAGE VALUES) Table 21

Number of Ductsin Ground

Spacing

Touching 0.30 m 0.45 m 0.60 m

600/1000volt cables

1900/3300volt cables

23456

0.900.830.790.750.73

0.880.800.760.720.69

0.910.850.810.780.76

0.930.880.850.830.81

0.940.900.880.860.85

0.930.880.850.830.82

0.950.910.890.880.87

0.960.930.920.910.90

23456

SPACING

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It is anticipated that many of the “in air” installations will be in buildings, and the ratings are therefore given on thebasis of an ambient air temperature of 30˚C, in accordance with IEE Wiring Regulations for Electrical Installations. Thisis in contrast to the value of 25˚C used in ERA 69-30 Part III for cables in air. Conversion to this or any other ambienttemperature is easily achieved by the use of the rating factors given below.

It should be noted that all ratings for cables run in free air have been based on the assumption that they areshielded from the direct rays of the sun without restriction of ventilation. The rating for cables subjected to directsunlight should be reduced to take account of this factor and further guidance on this subject is available onrequest.

Defined conditions of installation

The 'in-air' current ratings given in Tables 5 to 11 are based on the installation conditions in air as follows:

a) Single core cables

(1) Two single core cables are installed on above the other, fixed to the vertical surface of a wall or open cabletrench, the distance between the wall and the surface of the cable being not less than 20mm. Cables are installed at a distance between centres of twice the overall diameter of the cable, i.e. 2D, where D = overall diameter of cable.

(2) Three single core cables are installed in trefoil formation, fixed to the vertical surface of a wall or open cabletrench, the cables touching throughout and the distance between the wall and the surface of the nearest cablebeing not less than 20mm.

The cables are assumed to be remote from iron, steel, or ferro-concrete, other than the cable supports. Single core armoured cables to be electrically bonded at each end of the run.

b) Multicore cables

Cables of all types other than single core cables are installed singly, fixed to the vertical surface of a wall or open cable trench, the distance between the surface of the cable and the wall being not less than 20mm in every instance.

If it is necessary for cables to be installed at distances less than those described above, then the values tabulatedunder the heading "Clipped direct to a surface..." in the IEE Wiring Regulations should be employed.

CABLES INSTALLED IN AIR

RATING FACTORS FOR OTHER AMBIENT TEMPERATURES Table 22

Air temperature 25˚C 30˚C 35˚C 40˚C 45˚C 50˚C 55˚C

Rating Factor 1.04 1.0 0.96 0.91 0.87 0.82 0.76

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1.

5

2.5

4

6

10

16

25

35

50

70

95

120

150

185

240

300

400

500

630

800

1000

12

.1

7.41

4.

61

3.08

1.

83

1.15

0.

727

0.

524

0.

384

0.

268

0.

193

0.

153

0.

124

0.

0991

0.

0754

0.

0601

0.

0470

0.

0366

0.

0283

0.

0221

0.

0176

- - - - - -

1.2

0.

868

0.

641

0.

443

0.

320

0.

253

0.

206

0.

164

0.

125

0.

100

0.

0778

0.

0605

0.

469

0.

0367

0.

0291

- - - - -

8.14

6.

63

6.01

5.

24

4.56

4.

07

3.30

3.

03

2.48

2.

03

1.86

1.

41

1.16

0.

98

0.76

0.

65

- - - - -

0.62

0.

54

0.50

0.

47

0.42

0.

39

0.35

0.

32

0.29

0.

26

0.24

0.

17

0.15

0.

13

0.09

0.

08

8.

98

7.56

6.

37

5.85

4.

91

4.29

3.

21

2.60

3.

19

2.52

2.

10

1.89

1.

58

1.33

1.

02

0.87 - - - - -

6.

21

5.51

4.

88

4.59

4.

01

3.10

2.

64

1.69

1.

88

1.64

1.

14

1.04

0.

95

0.69

0.

61

0.55 - - - - -

8.

54

7.09

6.

27

5.40

4.

71

4.11

2.

96

2.41

2.

37

1.95

1.

60

1.32

1.

13

0.89

0.

76

0.62

0.

53 - - - -

5.

96

5.26

4.

81

4.31

2.

93

2.64

1.

58

1.42

1.

40

1.27

0.

87

0.78

0.

58

0.52

0.

47

0.42

0.

39 - - - -

7.

72

6.29

5.

41

4.91

4.

10

3.31

2.

93

2.38

1.

96

1.59

1.

30

1.11

0.

88

0.75

0.

61

0.53

0.

43 - - - -

5.

59

4.84

4.

31

3.02

2.

63

2.36

1.

57

1.41

1.

27

0.87

0.

77

0.57

0.

51

0.47

0.

42

0.38

0.

26 - - - -

- - - - -

2.42

1.

97

1.68

1.

61

1.54

1.

37

1.10

1.

00

0.86

0.

73

0.61

0.

53 - - - -

- - - - -

1.37

1.

22

1.13

0.

84

0.81

0.

77

0.54

0.

52

0.48

0.

43

0.40

0.

37 - - - -

Arm

our

Lead

Arm

our

Lead

Arm

our

Lead

Arm

our

Lead

Arm

our

Lead

600/

1000

V

Two

Cor

eS

ingl

e C

ore

Four

Cor

eTh

ree

Cor

eTh

ree

Cor

e

1900

/330

0VA

lum

iniu

mco

nduc

tor

Cop

per

cond

ucto

r

Nom

inal

Are

aof

Con

duct

or

mm

2

XL

PE in

sula

ted

Lea

d Sh

eath

ed A

rmou

red

Pow

er C

able

s to

BS

5467

and

EE

MU

A 1

33

Max

imum

resi

stan

ce (o

hms)

per

100

0 m

etre

s of c

able

at 2

0˚C

RE

SIST

AN

CE

OF

CO

ND

UC

TOR

, LE

AD

SH

EAT

H A

ND

AR

MO

UR

Tabl

e 23

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Table 24

SHORT CIRCUIT RATINGS – CONDUCTORS

The values of fault current given in the graph are based on thecable being fully loaded at the start of the short circuit (conductortemperature 90˚C) and a final conductor temperature of 250 ˚C.It should be ensured that the accessories associated with thecables are also capable of operation at these values of faultcurrent and temperature.

Note: With XLPE cables the use of soldered type connectors(instead of the compression type) is not recommended since theiruse in the system would limit the final conductor temperature to160˚C (and consequently reduce the fault current rating byapproximately 30 per cent).

Conductor size Short circuit ratings for 1 second in KAmm2 Copper conductor Aluminium Conductor

1.5 0.21 0.142.5 0.36 0.244 0.57 0.386 0.86 0.56

10 1.43 0.9416 2.29 1.5025 3.58 2.3535 5.00 3.2950 7.15 4.7070 10.01 6.5895 13.59 8.93

120 17.16 11.28150 21.45 14.10185 26.46 17.39240 34.32 22.56300 42.90 28.20400 57.20 37.60630 90.09 59.22800 114.40 75.20

1000 143.00 94.00

Note: For any other duration ‘t’seconds divide the givenvalue by t

Copper Conductors

FAU

LT C

UR

REN

T K

ILO

AM

PER

ES

DURATION OF SHORT CIRCUIT IN SECONDS

Aluminium Conductors

FAU

LT C

UR

REN

T K

ILO

AM

PER

ES

DURATION OF SHORT CIRCUIT IN SECONDS

100

10090807060

50

40

30

20

109876

5

4

3

2

1

908070605040

30

20

10987654

3

2

1

0.5 1.5 mm2

4 mm2

6 mm2

16 mm2

25 mm2

35 mm2

50 mm2

70 mm2

95 mm2

120 mm2

150 mm2

185 mm2

240 mm2

300 mm2

400 mm2

500 mm2

630 mm2

800 mm2

1000 mm2

0.10.1 0.2 0.3 0.4 0.5 0.6 0.8

0.7 0.91.0 2.0 3.0

0.1 0.2 0.3 0.4 0.5 0.6 0.8 1.00.7 0.9

2.0 3.0

2.5 mm2

300 mm2

240 mm2

185 mm2

150 mm2

120 mm2

95 mm2

70 mm2

50 mm2

35 mm2

25 mm2

16 mm2

10 mm2

23BICC

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4295

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4002

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168

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4038

4493

4981

7113

7996

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149

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423

796

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9- - -

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24 BICC

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2206

3424

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1271

1689

2128

2608

3913

4437

1666

2208

2706

3870

4573

5108

2071

2744

3696

4340

6586

7557

2611

3352

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4958

7330

8382

25BICC

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Voltage Drop is normally only if importance for cables of voltage rating 600/1000V or below. If the installation is to bein compliance with Regulation 525 of the 16th Edition of the IEE Wiring Regulations, it is stipulated that "the voltagedrop within the installation does not exceed a value appropriate to the safe functioning of the associated equipment innormal service. The requirement is deemed to be satisfied if the drop in voltage from the origin of the installation(usually supply terminals) and the fixed current using equipment does not exceed 2.5 per cent of the nominal voltage ofthe supply, disregarding starting conditions."

(Note: Diversity can be taken into account when calculating voltage drop.)

Since the actual power factor of the load is often not known, the most practical approach to the question of voltage dropis to assume the worst conditions i.e. where the phase angle of the load is equal to that of the cable. The voltage dropvalues in the table have been based on this assumption. For conductor sizes up to and including 120 mm the figuresprovided apply with sufficient accuracy where the power factor lies between 0.6 lagging and 1.0 and for cables wherethe power factor load does not exceed 0.8 lagging. Where the phase angles of the loads fall outside this range, the voltagedrop deducted from the tables may be unduly conservative and more exact methods of calculation should be employed.

The values of voltage drop for 600/1000V rated cables are given in the current rating tables.

In those cases where the actual current differs greatly from the tabulated current rating, the results obtained from thecables are only approximate; for a more accurate assessment, allowance should be made for the change in conductorresistance with operating temperature. Refer to following page and Table 27 for details. It should also be ensured thatthe cable size ultimately selected is capable of carrying the required current under the site conditions of installation.

Values of voltage drop are tabulated for a current of one ampere for a 1 metre run, i.e. for a distance of 1 metre alongthe route taken by the cables, and represent the effect of the voltage drop in all the circuit conductors. For balanced threephase ac circuits, the values relate to the line voltage. For any given run the values need to be multiplied by the lengthof the run (in metres) and by the current (in amperes) that the cables are able to carry.

Examples: Consider a route of 200 metres of 4 Core armoured cable to be installed in air and to carry 100 amperes loadper phase, with the supply voltage being 415 volts, three phase 50 Hz and the cable to be Copper XLPE/SWA/PVC.

Using the tables:

Let Vd be the voltage drop in volts.

Vd = mV x I x L or mV = Vd x 10001000 I x L

where I = Current in amperes L = Route length in metres mV = Approximate volt drop/ampere/metre

Assume maximum permissible volt drop = 2.5 per cent of 415 volts = 10.38 volts

Substitute for current, route length and maximum permissible volt drop

Then mV = 10.38 x 1000 = 0.52200 x 100

Select a cable from the relevant Current Rating Table 8 such that "mV value" from the voltage drop column is equal toor less than the 0.52 mV calculated, ensuring that it will carry the current. It will be seen that this value is 0.5 giving acable size of 95 mm2.

Note: Please refer to following 2 pages for additional information on voltage drop.

VOLTAGE DROP

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XLPE CABLE DATA FOR PARTIAL LOADS

The current ratings given in relevant tables of this publication assume that cables are fully loaded i.e. conductor operatingtemperature is 90˚C and conductor resistances at this temperature have been used in the tabulated figures of volt drop perampere per metre for various sizes of cables.

In many situations the conductor size which is ultimately chosen may not be carrying its maximum permissible current (i.e. its fullrated current) and consequently it will not be operating at its maximum designed temperature. Table 27 shows the reduced voltagedrop / ampere/metre data corresponding to reduced operating temperature due to reduced load currents. The first line is applicableto 90˚C conductor temperature. Examples are given below to illustrate situations where over-designing can be avoided. “Standardconditions” in the following refer to those obtained in the United Kingdom on which the current rating /voltage drop tables arebased. For situations other than “standard conditions” such as those in the Middle East, suitable rating factors can be applied forutilising data in Table 27 as shown in example (3) in the following:

It should also be ensured that the cable size ultimately selected is capable of carrying the required current under site conditions ofinstallation.Formula Vd = mV x I x L or mV = Vd x 1000

1000 I x Lwhere Vd = maximum acceptable volt drop (in volts)

I = current per phase (in amps)mV = appropriate volt drop (in mV/amp/metre)L = route length (in metres)

Examples: At standard defined conditions:1) Consider a route of 120 metres of four core copper XLPE/SWA/PVC to be installed in air (at standard conditions) and to carry300 amps per phase at 415 volts. Maximum voltage drop to be 2.5 per cent. 2.5 per cent of 415 V = 10.4 VSubstitute for current, route length and maximum volt dropmV = 10.4 x 1000 = 0.289 mV/A/m

300 x 120From Table 27, the first line of figures per conductor size (corresponding to IEE Wiring Regulations) and giving a voltage dropvalue less than 0.289 is 185 mm2. By studying the table to find a voltage drop value equal to, or less than the 0.289 calculated, butat the same time representing the 300 A load required, it will be seen that a voltage drop of 0.280 corresponds to a current of 305A and a reduced conductor size of 150 mm2. Therefore it is possible to select a 150 mm2 cable rather than the 185 mm2 cable firstindicated.The actual volt drop of this installation is Vd = 300 x 120 x 0.280 = 10.1 V

1000

2) Consider a route of 130 metres of four core copper XLPE /SWA/PVC cable to be installed partly in air, partly underground, andto carry 260 amps per phase at 380 V. Maximum voltage drop to be 3 per cent. (defined by system) 3 per cent of 380 V = 11.4 VSubstitute for current, route length and maximum volt dropmV = 11.4 x 1000 = 0.337 mV/A/m

260 x 130

Selecting a voltage drop corresponding to the maximum rating the size would be 150 mm2 but selecting from Table 27 such thatmV/A/m is equal to, or less than the 0.337 calculated and is capable of carrying 260 A (in ground and in air), it will be seen thatthis value is 0.333 for a 120 mm2 cable (instead of 150 mm 2).and the actual voltage drop = 260 x 130 x 0.333 = 11.3 V

1000(See Tables 12 to 22 for site conditions other than standard defined conditions)

Examples: At site conditions other than standard defined conditions3) Consider example (1) but at an ambient temperature of 45˚C. Derating factor for this temp. = 0.87 (see Table 22). Using thisfactor, calculate the ‘equivalent current’at standard conditions by dividing the actual current by the derating factor.Thus ‘equivalent current’ = 300 = 345 A

0.87and from previous example (1) the mV/A/m figure needs to be 0.289 or less. Selecting a cable from Max Rating figures as previously - the cable would be 185 mm2.However selecting from Table 27 with a current of 345A and a volt drop of 0.289 (or less), gives a cable size of 150 mm2 with avoltage drop value of 0.288 mV/A/m at 345A. (instead of the 185 mm2).and the actual voltage drop = 300 x 120 x 0.288 = 10.4 V

1000

For installations where XLPE insulated cables are not fully loaded andconductor operating temperatures are below 90˚C.

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999793898480746862

16

265260250245235225215205195

11511211010510097948984

70

251240230220210195185170150

0.6070.5990.5890.5800.5720.5620.5540.5450.536

185

463450430415395370345320290

0.2550.2520.2490.2460.2430.2400.2370.2350.232

460450435420405390375355335

2.502.502.472.432.392.352.312.272.23

Currentin ground

A

Voltagedrop

mV/A/m

Currentin air

A

Conductorsizemm2

215210200195190185175165155

0.8650.8520.8390.8260.8130.8000.7870.7740.761

197190180175165155145135120

50 150

406395375365345325305280250

0.3030.2990.2950.2920.2880.2840.2800.2770.273

405395385370360345330315295

400

728715685655620585545500450

0.1660.1630.1620.1610.1600.1590.1580.1570.156

667640620600580560535505475

315305300290280270255245230

150145140135130125120115110

25

131130125120110105999182

1.651.591.561.541.511.491.461.441.41

95

304295290270255240225210190

0.4460.4390.4330.4270.4210.4150.4080.4020.396

240

546530510490465440410375340

0.2110.2080.2060.2040.2030.2000.1990.1970.195

530515500485470450430410385

180175170165160150145140130

35

162155150145135130120110100

1.151.151.131.111.091.081.061.041.02

120

353340325310300280260240215

0.3660.3570.3520.3470.3420.3370.3330.3280.323

360350340330320305295280260

300

628605580555530500465430390

0.1850.1830.1810.1800.1790.1770.1760.1740.174

590575560540520500480455430

Currentin ground

A

Voltagedrop

mV/A/m

Currentin air

A

Conductorsizemm2

XLPE INSULATED CABLES - COPPER CONDUCTORSVOLTAGE DROP DATA FOR DIFFERENT LOADS

THREE AND FOUR CORE ARMOURED, PVC SHEATHED CABLES

Installation conditions for above ratings:Ambient temperature:30˚CGround Temperature: 15˚C

Soil Thermal resistivity:1.2 Km/WDepth of laying: 0.5m

600/1000 V Table 27

Conductorsizemm2

Currentin air

A

Voltagedrop

mV/A/m

Currentin ground

A

For other installation conditions, apply the appropriate rating factors. For installation in air, refer to table 22 and in ground, refer to tables 12 to 16.

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The following table gives the estimated impedance of copper phase conductor and steel wire armour in series, i.e. thecontribution to earth fault loop impedance by the cable, allowing for the estimated increase in temperature due to theflow of the earth fault current. The earth fault current is taken to be that which gives interruption in five seconds whenthe protective device is a standard type having a rating not higher than the current rating of the cable.

As per clause 522-08-04 of the 6th Edition of IEE Wiring Regulations, where the cable is not continuously supported itshall be supported by suitable means at appropriate intervals in such a manner that the cable does not suffer damage byits own weight.

CONTRIBUTION BY CABLE TO EARTH FAULT LOOP IMPEDANCE

CABLE SUPPORT SPACING

Table 28

Conductor

mm2

16

253550

7095

120

150185240

300400

6.67

5.874.023.55

2.982.11

-

---

--

6.42

4.353.773.17

2.731.981.79

1.231.100.97

0.89-

5.91

4.103.392.92

1.981.731.25

1.100.980.86

0.780.60

2 core

Contribution by cable to earth fault loop impedance milli ohms/metre

3 core 4 core

COPPER CONDUCTOR, XLPE INSULATED ARMOURED CABLES TO BS 5467600/1000 V

Note: For information on maximum length of cable that meets the earth fault loop impedance requirement for 5 seconddisconnection, refer to Ducab’s Technical Department.

30 BICC

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Lead sheathed power control auxiliary cables

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