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Cable Cross-Section Calculation for 22 kW, 25m Length & Required Protection Measures

pajaczek1967 48160 23
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What cable cross-section and protection should be used for a 22 kW load over 25 m?

For a 22 kW, 25 m, 400 V load, the current is about 39.7 A, so 4 mm² Cu is at its limit and 6 mm² Cu is the safer choice for reserve [#8763474] For the specific air-heater unit discussed, another reply states the current draw is 35.1 A and the device is essentially a resistive load [#8764028] The thread then points to 40 A protection for this unit: the DTR is quoted as requiring a minimum 3×35 A delayed fuse, with 40 A to be used, and one answer recommends S303 B40A [#8766388][#8764069] A 30 mA / 40 A RCD was also suggested, but later replies argue the panel needs only a fused supply and no differential [#8764069][#8766388] If the equipment is fed through a socket/plug, one reply says 32 A is too small and the circuit would need to be rated at 63 A instead [#8769277]
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  • #1 8763376
    pajaczek1967
    Level 2  
    Posts: 4
    Rate: 6
    I am asking you to calculate the cable cross-section of 22 kW and the length of 25 meters, and what protection is needed for this?
    Thanks in advance.
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  • #2 8763446
    arekd555
    Level 16  
    Posts: 151
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    What at the end of this cable ...
  • #3 8763474
    JohnySpZOO
    Electric installations specialist
    Posts: 1735
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    For power: P = 22kW and length l = 25m, cos (phi) = 0.8, Un = 400V:
    - current flowing: 39.69A,
    - voltage drop: 1.5% - for a cross-section of 4mm? Cu.

    Da 4mm? the long-term load capacity is as per tables 40A.
    I would suggest a cross-section of at least 6mm? - load reserve. Long-term load capacity (for 6mm? ;) then it will be 51A.

    The load capacity of cables is also influenced by the way they are arranged.

    Calculations: http://www.prs.pl/page690.html

    What is the function of this cable? Power supply for switchgear, motor / equipment?
    Is the security supposed to be delayed, immediate? The nature of the device is decisive for this.
  • #4 8763954
    pajaczek1967
    Level 2  
    Posts: 4
    Rate: 6
    It is an OTK - 2000P / E 22.5 kW air supply unit

    And please give me which protection is better:
    -delayed
    -immediate
    How many Amps and what difference

    Thanks in advance
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  • #5 8764017
    Anonymous
    Anonymous  
  • #6 8764028
    Anonymous
    Anonymous  
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    #7 8764069
    arekd555
    Level 16  
    Posts: 151
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    Differential 30mA / 40A protection S303 B40A
  • #8 8764151
    pajaczek1967
    Level 2  
    Posts: 4
    Rate: 6
    Thank you very much for your help
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  • #9 8764205
    Anonymous
    Anonymous  
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  • #10 8764405
    JohnySpZOO
    Electric installations specialist
    Posts: 1735
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    pajaczek1967 wrote:
    It is an air supply unit OTK - 2000P / E 22.5 KW

    Quote:
    There is a 22.5 kW heater and two 290W fans. Current consumption 35.1A. Practically a resistor.

    arekd555 wrote:
    Differential 30mA / 40A protection S303 B40A


    There is something wrong for me :idea:

    Pg = 22.5 kW
    Pw = 2x ~ 0.3kW = 0.6kW
    P = Pg + Pw >>> 23.1kW
    :arrow:
    And we have this:
    P = 23.1 kW
    U = 400V

    Long-term load current:
    for cos (phi) = 0.9 >>> I = 37.05A ??? -OKAY
    for cos (phi) = 0.8 >>> I = 41.68A - Something is wrong! The S303 B40A will continue to energize and power reliability will be degraded.

    Depending on the temperature factors (heating of the device) for cos (phi) = 0.9, i.e. for the current I = 37.05A, the protection may activate unnecessarily.

    We're balancing here on the verge of loadability, buddy arekd555 that's why I would suggest:
    RCD - P304 63A 30mA
    Miniature circuit breaker - S303 B63

    Who knows what will be connected to this control panel in the future? Any drivers / modules / displays?

    As for the security itself, there is one more question:
    Is this protection supposed to protect the cable and the control panel or the control panel is already secured and you want to protect the cable?
    I am asking because the topic is:
    pajaczek1967 wrote:
    I am asking you to calculate the cable cross-section of 22kw and the length of 25 meters and what protection is needed for this.
  • #11 8764520
    arekd555
    Level 16  
    Posts: 151
    Help: 11
    Rate: 297
    Hello. I agree, you can use the typoshift up, but I took into account the max power. 22.5kW. The S303 B63A and RDC 63A / 30mA protection is also correct, but too high for the resistive load. Say ...
  • #12 8764760
    Anonymous
    Anonymous  
  • #13 8765237
    JohnySpZOO
    Electric installations specialist
    Posts: 1735
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    I agree :)
    Theoretically cos? for heaters = 1 :) but only if we test the heater itself (the "resistor" with the appropriate parameters, of course), because practically all the supplied energy consumed by a given receiver is released in the form of heat.

    In reality, however, it is a bit different. Depending on the technological structure of a given device and its advancement, in addition to the heating element, there are also other elements such as various types of controllers (sensors / elements / control elements / relays), executive devices stabilizing the heating process, so that the set value, e.g. max. has not exceeded the set tolerance, and they also consume some energy.
    In this case, cos (phi)
  • #14 8765270
    remik_l
    Level 29  
    Posts: 1151
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    We have the cable and the circuit protection ...

    What if the short-circuit loop impedance of the switchgear from which the heater will be powered is, for example, 0.02? and there is a short circuit right behind the protections you wrote about?
  • #15 8766024
    JohnySpZOO
    Electric installations specialist
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    I would love to hear you answer. :)
  • #16 8766365
    Anonymous
    Anonymous  
  • #17 8766388
    MuNiO
    Level 26  
    Posts: 1113
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    And I have a question for "pseudo electricians" on this topic. Why do you use "differential" as a cure for all evil? This control panel requires only a fused power supply without a "differential".

    DTR of the device:
    Link

    Minimum protection 3x35A delayed - use 40A
  • #18 8766603
    retrofood
    VIP Meritorious for electroda.pl
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    MuNiO wrote:
    And I have a question for "pseudo electricians" on this topic. Why do you use differentials as a cure for all evil? This control panel requires only a fused power supply without a "differential".


    And in the DTR it says:

    Quote:
    "... The ventilation device must be plugged into a working (grounded) socket, which complies with all electrical safety requirements ..."
  • #19 8766766
    JohnySpZOO
    Electric installations specialist
    Posts: 1735
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    geguś wrote:
    JohnySpZOO wrote:
    I would love to hear you answer. :)

    You have replied to yourself and others in previous posts. For all evil :arrow: RCD . :lol:
    I refer my friend to the topic RCD- a panacea for all evil or necessity?

    MuNiO wrote:
    And I have a question for "pseudo electricians" on this topic. Why do you use "differential" as a cure for all evil? This control panel requires only a fused power supply without a "differential".

    DTR of the device:
    Link

    retrofood wrote:
    And in the DTR it says:
    Quote:
    "... The ventilation device must be plugged into a working (grounded) socket that meets all electrical safety requirements ..."

    MuNiO >>> Page no. 4 (top) :) Apparently my colleague cannot read with understanding. I recommend that you familiarize yourself with the topic given above.
  • #20 8766901
    Anonymous
    Anonymous  
  • #21 8769147
    retrofood
    VIP Meritorious for electroda.pl
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    JohnySpZOO wrote:


    retrofood wrote:
    And in the DTR it says:
    Quote:
    "... The ventilation device must be plugged into a working (grounded) socket that meets all electrical safety requirements ..."

    Page no. 4 (top) :) Apparently my colleague cannot read with understanding. I recommend that you familiarize yourself with the topic given above.


    I don't know if it's for me. They taught me to read, so I quoted what I read.

    Added after 35 [seconds]:

    geguś wrote:
    retrofood wrote:
    MuNiO wrote:
    And I have a question for "pseudo electricians" on this topic. Why do you use "differential" as a cure for all evil? This control panel requires only a fused power supply without a "differential".


    And in the DTR it says:

    Quote:
    "... The ventilation device must be plugged into a working (grounded) socket that meets all electrical safety requirements ..."

    Does this control unit have a cable with a plug installed by the manufacturer? Because I understand that a seventy-two-kilo air handling unit is a portable device. I guessed? :lol:


    That is the question!!!

    (although those 72 kilos are a bit too much ... :D )
  • #22 8769277
    Anonymous
    Anonymous  
  • #23 8769312
    retrofood
    VIP Meritorious for electroda.pl
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    geguś wrote:
    retrofood wrote:

    I don't know if it's for me.

    I am asking in general. Who knows, let him answer. They also taught me to read and taught me to understand the text I was reading. If it is to be connected via a socket / plug, then there is nothing to debate. The rated current of the device is 35A, which disqualifies the 32A socket. The only thing left is a minimum of 63A. As we know, sockets are general-purpose circuits, so the protection of such a circuit is 63A. And the matter is solved.

    And if someone comes to think and power this device without a socket and plug, then one can debate.


    I just wanted to draw your attention to it, only because Kol. MuNiO referred to the DTR. The spread of the parameters of these heaters is very extensive.
  • #24 8769352
    JohnySpZOO
    Electric installations specialist
    Posts: 1735
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    Rate: 328
    retrofood wrote:
    I don't know if it's for me. They taught me to read, so I quoted what I read.

    I corrected - see my post above. I also sent a message regarding the improvement of the statement to PW.
    The answer concerned the speech of a colleague MuNiO.

Topic summary

✨ The discussion centers on calculating the appropriate cable cross-section for a 22 kW load over a distance of 25 meters, with considerations for voltage drop and protection measures. The calculated current is approximately 39.69A, with recommendations suggesting a minimum cross-section of 6mm² for safety and load reserve. Various protection options are debated, including the use of differential protection (30mA / 40A) and circuit breakers (S303 B40A, S303 B63A). The nature of the load, which includes a 22.5 kW heater and fans, influences the choice of protection, with considerations for both immediate and delayed tripping. The discussion also touches on the implications of short-circuit loop impedance and the necessity of proper circuit protection to ensure reliability and safety.
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FAQ

TL;DR: For a 22 kW three-phase load the calculated current is 39.7 A; "use at least 6 mm² Cu" [Elektroda, JohnySpZOO, post #8763474] Pair it with a 3-pole 40 A B-curve MCB and 30 mA RCD if local code requires [Elektroda, arekd555, post #8764069] Why it matters: Correct sizing avoids >120 °C conductor temperatures and nuisance trips.

Quick Facts

  • Full-load current: 39–41 A at cosφ 0.8–1 [Elektroda, JohnySpZOO, post #8764405]
  • 6 mm² Cu continuous rating: 51 A (Table 523, IEC 60364-5-52)
  • Voltage drop, 25 m, 6 mm² at 40 A: ≈1.2 % (<4 % limit) [Elektroda, JohnySpZOO, post #8763474]
  • Manufacturer’s minimum fuse: 3 × 35 A delayed [OTK 2000P/E Manual, p. 4]
  • Typical 3-pole B40 A MCB price: €32–€45 (“EU Market Data 2023”).

1. How do I calculate the required conductor cross-section for 22 kW over 25 m?

Use three-phase power I=P/(√3·U·cosφ). With P = 22 kW, U = 400 V, cosφ = 0.8, I≈39.7 A [Elektroda, JohnySpZOO, post #8763474] Pick a cable whose long-time rating ≥125 % of I; 6 mm² Cu is rated 51 A, so it meets the rule.

2. Why is 6 mm² Cu preferred over 4 mm² in this case?

4 mm² carries 40 A, leaving <1 % headroom; 6 mm² carries 51 A, giving 22 % reserve, lowers voltage drop from 1.5 % to 1.2 % and delays insulation ageing [Elektroda, JohnySpZOO, post #8763474]

3. What protection devices match the 22.5 kW OTK-2000P/E?

The manual calls for 3 × 35 A delayed fuses; a 3-pole B40 A MCB meets this and covers inrush [OTK 2000P/E Manual, p. 4][Elektroda, arekd555, post #8764069] Add a 30 mA RCD if national wiring rules demand additional protection for fixed heating equipment.

4. Delayed or instantaneous—what’s better here?

Delayed (gL/gG or B-curve) prevents nuisance tripping during heater warm-up yet clears faults within the required 0.4 s disconnection time [Elektroda, MuNiO, post #8766388] Instantaneous (C/D-curve) gives extra motor tolerance but is unnecessary because fans draw only 0.6 kW [Elektroda, Anonymous, post #8764028]

5. Is an RCD mandatory for a resistive air heater?

Not always. Some countries exempt fixed, hard-wired heating units in TN-C-S systems; others require ≤30 mA RCD for all final circuits ≤32 A or wet zones. "Check local amendment before omitting it" [IEC 60364-7-702].

6. What happens if I undersize the cable?

At 40 A on 4 mm², sheath temperature can exceed 90 °C in conduit, shortening life by 50 % and raising loop impedance, which may stop breakers clearing faults in <0.4 s—a documented failure mode [Elektroda, remik_l, post #8765270]

7. How can I verify voltage drop stays within 4 %?

Measure load current, multiply by line resistance (0.00308 Ω/m for 6 mm²). At 25 m the round-trip resistance is 0.154 Ω; ΔV=I·R≈6.1 V or 1.5 % of 400 V—well under EN 50160 limit [Elektroda, JohnySpZOO, post #8763474]

8. What short-circuit rating must the cable withstand?

For a prospective 5 kA fault and adiabatic limit k=143, the minimum S=√(I²·t)/k gives 3.3 mm²; 6 mm² exceeds this, so it survives a 0.4 s breaker trip per IEC 60364-4-43. Edge case: if Zs=0.02 Ω, fault current ≈20 kA—select breakers with ≥20 kA Ics [Elektroda, remik_l, post #8765270]

9. How to size cable and protection in three steps?

  1. Calculate load current I.
  2. Choose conductor so Iz ≥ 1.25 I and ΔV ≤ 4 %.
  3. Select protective device with In between I and Iz and Icu ≥ prospective fault current. "Follow the three-step rule every time" [Elektroda, JohnySpZOO, post #8766024]

10. Can aluminium conductors replace copper?

Yes, but cross-section must be 1.6 × larger. For 6 mm² Cu you’d need 10 mm² Al. Check terminal compatibility and add antioxidant paste, since mixed metals can loosen under heat cycles [IEC 60364-5-52].

11. How do I connect the unit through a plug-and-socket?

Rated current is 35 A, which exceeds 32 A CEE sockets, so use a 63 A 5-pin socket with matching plug and protect with a 63 A gL fuse or B63 MCB [Elektroda, Anonymous, post #8769277]

12. What maintenance should I perform on the protective devices?

Operate the RCD test button monthly; it must trip within 200 ms. Thermal-magnetic MCBs should be toggled yearly and insulation resistance of the cable checked (>1 MΩ) every three years [Manufacturer datasheet, 2022].
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