Basic Circuit Design

(revision 2330 Unit 3).

Stories of Ib , In , It & volt drop -
Presented by: Rob Pettit

Updated to 17th Edition OSG amendment 1 (green

cover).

1
 Basic Requirements.
Before we install or modify a circuit, we must make
sure
1. That we calculate the total current that the circuit will
need to carry in relation to the power of the connected
load.
2. That we use the correct specification & rating of
protective device suitable for that load / current.
3. That we use a cable large enough so that it will always be
protected by the fuse or circuit breaker (MCB) from
damage due to over-current, taking into account any
correction factors applicable.
4. That earth loop impedance (Zs) is not excessive, so as to
achieve the required disconnection time for the circuit.
5. That volt drop for the circuit is within the tolerances
allowed.
2
 Step 1
Calculate Design Current (Ib).

The design current can

be calculated using the
formulae:
Ib = P
V
P = Power of load (watts)
P
I=P

V I
V = Supply voltage (volts)
V

3
 Calculate Design Current (Ib).

Example: A home sauna has a power rating of 4000 watts (4kW).

If the mains voltage is 230V, what current is the sauna drawing?

Ib = P Ib = 4000 (W) Ib = 17.4 Amps

V 230 (V)

230V
= 17.4A

4
 Calculate Design Current (Ib).

Examples: For the following loads, calculate the design current

rounded up to 2 decimal places (e.g. 2.1739A + 2.17A etc.)

To convert KW to watts, multiply x 1000.

Wattage Voltage Ib
500w 230

2.25kW 240

1700w 233

9.5kW 238

1750w 110
5
 Calculate Design Current (Ib)
Solution.

Examples: For the following loads, calculate the design current

rounded up to 2 decimal places (e.g. 2.1739A + 2.17A etc.)

To convert KW to watts, multiply x 1000.

Wattage Voltage Ib
500w 230 2.17A
2.25kW 240 9.38A
1700w 233 7.3A
9.5kW 238 39.92
1750w 110 15.91
5.2kW 230 22.61
6
 Step 2 Selection of Protective
Device Rating (In).

Once Ib (full load design current) is known, the

rating of the protective device (In) can be selected
using the rule -
In = 16 amps

In Ib

In simple terms, this states that the rating of

the protective device (In) must be greater than
or equal to the full load design current (Ib)
common sense, otherwise the protective device
would nuisance trip.
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 Selection of Protective Device
Rating (In).
The available types & ratings of protective devices can be found in
columns 1 and 2 of table 7.1(i) pg. 60 of the IEE 17 th Edition On-Site-
Guide (OSG), or from manufacturers / wholesalers catalogues.
Decide which rating of device you would use for the loads calculated
earlier, based upon the rule In Ib
Wattage Voltage Ib Type In
500w 230 2.17A BS 3036

2.25kW 240 9.38A BS 1361

1700w 233 7.3A BS 88

9.5kW 238 39.92 B MCB

1750w 110 15.91 BS 3036

8
 Selection of Protective Device
Rating (In) - Solution.
The available types & ratings of protective devices can be found in
columns 1 and 2 of table 7.1(i) pg. 60 of the IEE 17 th Edition On-Site-
Guide (OSG), or from manufacturers / wholesalers catalogues.
Decide which rating of device you would use for the loads calculated
earlier, based upon the rule In Ib
Wattage Voltage Ib Type In
500w 230 2.17A BS 3036 5A
2.25kW 240 9.38A BS 1361 10A
1700w 233 7.3A BS 88 10A
9.5kW 238 39.92 B MCB 40A
1750w 110 15.91 BS 3036 20A
9 5.2kW 230 C MCB
 Step 3 Select Cable Size for
Current Carrying Capacity (It).

Once we have decided upon a protective device

rating (In), we must select a cable size large
enough to carry all of that current (amps) -

It I n
In simple terms, this states that the rating of the
cable (It) must be greater than or equal to the
current rating of the protective device common
sense, otherwise the cable could become the fuse!
10
 Select Cable Size for Current
Carrying Capacity (It).

Assuming we are using PVC flat (T&E) type cable, the tabulated
current carrying capacity (It) for different sizes of cable can be
found in table 7.1 (ii) / pg. 69 of the On-Site-Guide (OSG). For
other types of cable, refer to Appendix F.
Decide which rating / size of cable you would use for the
protective devices chosen earlier, based upon the rule It In
and assuming the cable is clipped direct (installation reference
method C). We will discuss the other installation methods later.

Example:
Wattage Voltage Ib Type In It / size
5.2kW 230 22.61A C MCB 32A 37A / 4.00mm2
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 Select Cable Size for Current
Carrying Capacity (It).

Decide which rating / size of cable you would use for the protective
devices chosen earlier, based upon the rule It In and assuming the
cable is clipped direct (installation reference method C). We will
discuss the other installation methods later.
Wattage Voltage Ib Type In It / size
500w 230 2.17A BS 3036 5A
2.25kW 240 9.38A BS 1361 10A
1700w 233 7.3A BS 88 10A
9.5kW 238 39.92 B MCB 40A
1750w 110 15.91 BS 3036 20A
12 5.2kW 230 22.61 C MCB 32A 37A / 4.00mm2
 Select Cable Size for Current
Carrying Capacity (It) Solution.

Decide which rating / size of cable you would use for the protective
devices chosen earlier, based upon the rule It In and assuming the
cable is clipped direct (installation reference method C). We will
discuss the other installation methods later.
Wattage Voltage Ib Type In It / size
500w 230 2.17A BS 3036 5A 16A / 1.00mm2

2.25kW 240 9.38A BS 1361 10A 16A / 1.00mm2

1700w 233 7.3A BS 88 10A 16A / 1.00mm2

9.5kW 238 39.92 B MCB 40A 47A / 6.00mm2

1750w 110 15.91 BS 3036 20A 20A / 1.50mm2

5.2kW 230 22.61 C MCB 32A 37A / 4.00mm2

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 Temperature of Cables.

When selecting & installing cables, we have to

ensure they will not be damaged or degraded by
getting too hot, either as a result of current
passing through them or from external heat
sources.
All PVC (thermo-plastic) cable and flex has a
maximum operating temperature of 700C
If the ambient temperature is greater than 300C or
the cable is not clipped direct during use, a de-
rating factor must be applied often resulting in a
larger cable being required for the same load.
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 Installation Method C.

Clipped
direct or
embedded in plaster.

The best method.

15
 Installation Method B.

Runin conduit or
trunking.

16
 Installation Methods
100, 101 & 102.

Method 102

In contact with
thermal insulation.

See following for

further details
OSG: Pgs 69 70.

Method 100

17
 Installation Method 103.

To be avoided, as the
thermal effect can halve
the current carrying
capacity compared to a
cable clipped direct
(method C).

Ref: OSG: Pgs 69 70.

Surrounded by thermal
insulation 5cm.

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 Effects of Thermal Insulation.
It can be seen from OSG table 7.1 (ii) that the cable size may
need to be increased for our circuits if the cable is not
clipped direct (installation method C).
Recalculate the cable size for the following methods.

Watts Volts Ib Type In Method It / size

500w 230 2.17A BS 3036 5A 103

2.25kW 240 9.38A BS 1361 10A 102

1700w 233 7.3A BS 88 10A 101

9.5kW 238 39.92 B MCB 40A A

1750w 110 15.91 BS 3036 20A B

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 Effects of Thermal Insulation -
Solution.
It can be seen from OSG table 7.1 (ii) that the cable size may
need to be increased for our circuits if the cable is not
clipped direct (installation method C).
Recalculate the cable size for the following methods.

Watts Volts Ib Type In Method It / size

500w 230 2.17A BS 3036 5A 103 8A / 1.00mm2
2.25kW 240 9.38A BS 1361 10A 102 13A / 1.00mm2
1700w 233 7.3A BS 88 10A 101 10.5A / 1.00mm2
9.5kW 238 39.92 B MCB 40A A 44A / 10.00mm2
1750w 110 15.91 BS 3036 20A B 23A / 2.50mm2
5.2kW 230 22.61 C MCB 32A 102 35A / 6.00mm2
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 Voltage Drop.

21 3/13/17
 Voltage Drop.

As circuit conductors get longer their

resistance increases (more ohms ).
When current (amps) flows in the circuit
this resistance causes a loss of voltage in
the cable, known as volt drop.
This is a result of Ohms Law, where
Voltage (drop) = Current x Resistance (V = I x R),
where I is the amps drawn by the load & R is the
resistance of the cable conductors.
22 3/13/17
 Hot Water Immersion Heater
Effects of Volt Drop.
1.5mm2 heat
230V a.c. Long 2.5mm2 Less voltage resistant (HR) flex.
PVC/PVC flat cable at control
T&E).

Volt drop along cable

Fused time
B 16A MCB
control.
or 15A fuse.

As the cable gets longer the volt drop will increase

The time control may not work properly.
The immersion heater will take longer to heat up.
23 3/13/17
 How much Volt Drop are we
Allowed?

Lighting circuit 3%
6.9 volts for a 230v supply.
Equal to 223v minimum at load terminals.

Other circuits 5%
11.5 volts for a 230v supply.
Equal to 218.5v minimum at load terminals.

24 3/13/17
OSG: Appendix F pg. 145

Calculating Volt Drop.

We can calculate the volt drop on a circuit using the formulae

below and the tables in appendix F of the On-Site-Guide.
For example, using table F6 (pg. 155) for PVC flat cable
(T&E), we can calculate the total volt drop where:
mV/A/m = milli-volts per amp per metre (resistance per
metre of the cable) column 8.
Ib = design current / L = circuit length
And dividing by 1000 to convert from milli-volts to volts.

Voltage drop = (mV/A/m) x Ib x L = _______ V

1000
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 Example Calculating Volt Drop
For our 230v 3kW immersion heater wired in
2.5mm2 PVC flat cable with a circuit length of 19
metres:
Voltage drop = (mV/A/m) x Ib x L = _______ V
1000

Voltage drop = 18 x 13 x 19
= 4.47 V
1000

Is this a pass?
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 The End.

27
 How long can circuits be before Zs
& volt drop become too high?

On-Site-Guide (OSG) table 7.1 (i) / pg. 60 gives the

maximum lengths of circuits using flat twin & earth
type cable in TN installations.

E.g. For our immersion heater radial circuit wired in

2.5mm2 cable and protected by a type B 16A MCB to
BS EN 60898
Maximum length is 40 metres.
What would we need to do if the circuit required was 45
metres long?

28 3/13/17
 How long can circuits be before Zs
& volt drop become too high?

It can be seen that using a 4mm2 cable would

allow a circuit length up to 66 metres.
We should not, however, use a smaller cable for
the typical & Standard circuit arrangements
discussed earlier
i.e. 2.5mm2 cables for immersion heaters and socket
circuits etc.
For TT installations protected by RCDs, the
values for a TN-C-S system may be used.

29 3/13/17
 Worked examples using table 7.1
for Standard Circuits.
What is the cable size / maximum length to be
used?
1. Ring circuit, 30A BS 3036 re-wireable fuse, installation
method C, TN-S system with RCD.
_______________ or _________________
2. Outdoor lighting circuit, 6A type B MCB, installation
method 101, TN-C-S system without RCD.
_______________ or _________________
3. Immersion heater, 15A BS 1361 cartridge fuse,
installation method 102, TT system.
_______________ or _________________

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OSG: Appendix F pg. 145 -

Correction Factors.
We have already seen from OSG table 7.1(ii) - pg.
69, that if a cable is surrounded by thermal
insulation along its whole length (method 103) it
halves the current carrying capacity of the cable
compared to clipped direct (method C). This
represents a derating factor.
Other correction factors can be applied using the
formula -

It In
Correction factors
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OSG: Appendix F pg. 145 -

Correction Factors.

Factor: For: Table/Value:

Ca ambient temperature F1

Ci thermal insulation F2

Cg grouping F3

semi enclosed fuses to BS

Cf 0.725
3036.

Where more than one correction factor applies, they must be multiplied.
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 Some Example of Applying
Correction Factors.
If our immersion heater circuit was protected by a
15A rewireable fuse to BS 3036 and the circuit
cable was bunched with 3 other circuits in PVC
trunking (method B table 7.1(ii) pg. 69).

It In It 15
Correction factors 0.725 x 0.70

What would the cable size need to be

It 29.56A increased to? (see table 7.1(ii) OSG pg. 69)
33
 Final Notes.

Where a cable size is chosen using OSG

table 7.1(i)
1. Correction factors have already been applied in
accordance with section 7 (for a re-wireable
fuse, ambient temperature, limited grouping and
installation method).
2. So long as the circuit lengths indicated are not
exceeded, volt drop and loop impedance will not
be excessive.

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 The End.

Any questions?

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