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IEC 61851-1 / IEC 60364-7-722 / IEC 6295510 min read

Worked Example: Single Charge Point Sizing, a TN-C-S Earthing Trap, and Multi-Point Site Diversity

One 32A Mode 3 charge point, a common earthing mistake the calculator catches automatically, and how a Load Management System can roughly halve a 10-point site's feeder size.

Scenario

Charge point modeMode 3 (AC, with communication)
Rated current / voltage32 A, 400 V 3-phase
Circuit route length25 m, Method C, Cu/XLPE
Earthing system (for illustration)TN-C-S (PME)
Site size10 charge points
Site feeder length40 m

Step-by-step calculation

Step 1: Size the single charge point's circuit cable and breaker

Ib = ratedCurrentA = 32 A
Selected cable: 4 mm², derated ampacity 40 A, voltage drop 3.81% (≤5% limit — PASS). Breaker: 32 A (next standard size ≥ Ib)

Step 2: Check the earthing system for a TN-C-S (PME) conflict

A TN-C-S supply carries a combined protective-and-neutral (PEN) conductor upstream of the property — IEC 60364-7-722 prohibits extending a PEN conductor into the final circuit feeding an EV charge point, because a lost PEN connection could otherwise put dangerous voltage onto the vehicle's exposed metalwork.

Step 3: Confirm the RCD choice is compliant

Step 4: Size the site feeder for 10 points with no Load Management System

IEC 60364-7-722.311 requires a diversity factor of 1 (no reduction at all) when there is no LMS — every point must be assumed capable of drawing full rated current simultaneously.

rawA = numPoints x perPointA diversifiedA = rawA x diversityFactor
10 x 32 = 320 A 320 x 1 (no LMS)
diversifiedA = 320 A → feeder sized to 120 mm², derated ampacity 322 A, voltage drop 2.00% (≤5% — PASS)

Step 5: Re-size the same 10-point site with a Load Management System declared

diversifiedA = rawA x diversityFactor
320 x 0.6 (LMS-declared factor)
diversifiedA = 192 A → feeder drops to 70 mm², derated ampacity 229 A, voltage drop 2.10% (≤5% — PASS)

Result summary

CheckRequirementActualStatus
Single charge point voltage drop≤ 5%3.81%✓ PASS
Earthing check (TN-C-S)No PEN in final circuitWarning triggered — conversion required✗ FAIL
10-point feeder, no LMSSupport 320 A120 mm², 322 A capacity✓ PASS
10-point feeder, with LMS (0.6)Support 192 A70 mm², 229 A capacity✓ PASS
The single 32 A charge point circuit sizes cleanly to a 4 mm² cable and 32 A breaker. On a TN-C-S supply, the calculator flags a mandatory earthing conversion before the circuit can be considered compliant. At full 10-point site scale, declaring a Load Management System with a 0.6 diversity factor drops the required feeder from 120 mm² (no LMS, 320 A) to 70 mm² (with LMS, 192 A) — a substantial reduction, but one that is only permitted with an LMS in place; without one, the code requires designing for the full undiversified load.

Key insight: Diversity factors for EV sites are not a general convenience — IEC 60364-7-722.311 ties the right to apply any diversity below 1.0 directly to having a Load Management System in place. Without an LMS, every charge point must be assumed capable of running at full rated current at the same time, which is why the 'no LMS' feeder here has to support the full 320 A raw demand rather than any reduced figure.

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Frequently asked questions

Why does a TN-C-S supply specifically get flagged as a problem, when TN-S and TT don't?

In a TN-C-S (PME) system, the neutral and protective earth share a single PEN conductor for part of the network — if that PEN conductor breaks upstream, the property's earth terminal can float up to line voltage. On a normal socket circuit this is a recognized but generally low-frequency risk; on an EV charge point, a person may be standing on damp ground with one hand on a metal vehicle chassis connected to that same earth, which is exactly the scenario IEC 60364-7-722 singles out with mandatory extra protection (PEN conductor exclusion from the final circuit, open-PEN detection, or a local TT-style electrode).

What exactly does the LMS-declared diversity figure of 0.6 represent, and where does it come from?

It is not a fixed code value — IEC 60364-7-722 deliberately leaves the exact figure to the Load Management System's own real-time control strategy and the site design, which is why this calculator's note explicitly says to 'use your LMS/DSO-approved figure and verify it independently' rather than presenting 0.6 as a universal constant; a different LMS product or site agreement could justify a different figure entirely.

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