Buying guides

Circuit breaker and cable cross-section: how to choose

A breaker protects the cable, not the appliance: so its rating is chosen for the cross-section of the circuit, not for the power of the load. Below: curves B, C and D, a conservative “cross-section — breaker” table for copper wiring, 30 mA RCDs for damp areas and an example switchboard for a flat.

What a breaker does and what the figures mean

A circuit breaker opens the circuit in two cases: on overload (a current slightly above the rating for a long time — the thermal release trips within minutes) and on a short circuit (a current many times higher — the magnetic release trips within milliseconds). Both protect the cable insulation from overheating and fire. The appliance behind the breaker is protected by its own fuse or electronics.

On the case: C16 — curve C, rated current 16 A; 4500 or 6000 — breaking capacity in amperes, the highest short-circuit current the breaker will interrupt without being destroyed; 1P/2P/3P — the number of poles. For flats and offices 4.5 kA is usually enough; closer to a substation and in industrial switchboards take 6 kA and above.

Curves B, C and D

CurveInstantaneous tripWhere it is used
B3–5 × InLighting, sockets without motors, long runs and networks with a low short-circuit current (rural areas, the far end of a line)
C5–10 × InThe standard for flats, offices and shops with mixed loads: fridge, vacuum cleaner, power tools
D10–20 × InMotors, compressors, transformers, welding — high starting currents

The curve does not affect overload protection — the thermal part is the same. It only determines at what brief current surge the breaker trips instantly. A C breaker on a lighting circuit will work, but a B breaker clears a short circuit faster where the fault current is low.

Cable cross-section and breaker rating

There is one rule: the breaker rating must not exceed the continuous current rating of the cable. For copper conductors in typical domestic wiring (concealed, several cables side by side, ambient temperature up to 30 °C) the conservative values below apply. They follow established practice under the PUE (the Ukrainian Electrical Installation Rules); a single cable run on the surface can carry more current, but the breaker rating is raised only after a calculation.

Copper conductor cross-sectionBreakerApproximate load, 220 VTypical circuits
1.5 mm²10 Aup to 2.2 kWLighting, ventilation. 16 A on 1.5 mm² is seen, but it is the limit — we do not recommend it
2.5 mm²16 Aup to 3.5 kWSockets, washing machine, water heater up to 3 kW, air conditioner
4 mm²25 Aup to 5.5 kWHob up to 5 kW, built-in oven, instantaneous water heater
6 mm²32 Aup to 7 kWElectric cooker, high-power hob, incoming supply of a small flat
10 mm²40 Aup to 8.8 kWIncoming supply of a flat or a house (according to the allocated capacity)

An aluminium conductor carries less: for the same breaker take the next cross-section up. Long runs over 25–30 m are checked for voltage drop: if it exceeds 3–5 %, the cross-section is increased regardless of the current.

RCDs and RCBOs

An RCD (residual current device) responds to leakage current — to earth or through a person — and disconnects the circuit within tens of milliseconds. It does not protect against overload, so it is installed together with a breaker or replaced by an RCBO, which combines both functions in one module.

  • 30 mA — sockets in damp areas and socket circuits in general: bathroom, kitchen, outdoors, garage, washing machine, water heater. This is the threshold for protecting people.
  • 10 mA — individual high-risk circuits: shower room, children’s room, jacuzzi.
  • 100–300 mA — a fire-protection RCD at the incoming supply of a house, selective (time-delayed) so that it does not trip before the circuit RCDs.

The rated current of an RCD must be no lower than that of the breaker in front of it: after a C25 breaker — a 25 or 40 A RCD. On a lighting circuit an RCD is not mandatory, but it does no harm.

Switchboard layout and selectivity

The incoming breaker is chosen by the allocated capacity and the incoming cable; the circuit breakers are one or two steps smaller, so that a short circuit in a socket trips only its own circuit, not the whole flat. A voltage relay goes right after the incoming breaker: it disconnects everything on a surge above 250–260 V or a sag below 170–190 V and reconnects after a delay. A modular contactor switches heavy circuits on a signal from a timer, a push-button or a relay: workshop lighting, a water heater on a schedule, a load fed from an inverter.

Each circuit gets its own breaker and its own cable. Do not combine lighting and sockets on one circuit: when a breaker trips, the lights should stay on.

Example: switchboard for a one-room flat

CircuitCableBreakerRCD
Incoming supply10 mm²C40 2PFire-protection 63 A 300 mA (selective), voltage relay 63 A
Lighting1.5 mm²B10 or C10 1P—
Sockets, room and hallway2.5 mm²C16 1P40 A 30 mA, shared with the kitchen
Sockets, kitchen2.5 mm²C16 1P40 A 30 mA
Washing machine and bathroom2.5 mm²C16 1PRCBO 16 A 30 mA
Water heater2.5 mm²C16 1PRCBO 16 A 30 mA
Hob6 mm²C32 2PRCBO 32 A 30 mA
Air conditioner2.5 mm²C16 1P—

About 19 modules in total: a 24-module enclosure leaves room for future circuits. Installation and connection are done by a qualified electrician; this table is for drawing up a specification and talking to them in the same terms.

Common mistakes

  • A breaker sized “for the appliance” — C25 on 2.5 mm² cable: the cable will overheat and the breaker will not trip on the overload.
  • One RCD for the whole flat — a leak in the washing machine turns off the lights in the entire flat; split the circuits into groups.
  • An RCD rated lower than the breaker — the RCD contacts overheat; it is not designed for that current.
  • No voltage relay — a broken neutral in the building’s riser puts 380 V on the sockets and burns out appliances in seconds.
  • Aluminium and copper twisted together — galvanic corrosion, heating, fire; connect them only through terminal blocks.

Engineering calculation

Which breaker and cable the line needs

Enter the power, supply and line length to get the design current, breaker rating, copper cable cross-section and voltage drop.

Indicative: copper in a wall or conduit, cos φ 0.95, C characteristic, voltage drop up to 5% for power circuits and up to 3% for lighting. The final choice follows the project and the wiring regulations (PUE), allowing for the installation method and temperature.

3,5 kW
25 m
Supply
Purpose
Current0 A
BreakerC16
Copper cable3×2,5 mm²
Voltage drop0 %

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