TECHNICAL TABLES AND FORMULAE

Motor Currents
Approximate current per phase for AC Motors at full load, assuming
average efciency and Power Factor.

Three Phase Formulae

kW

= Line Amps x Line Volts x 1.732 x P.F

1000

kVA

= Line Amps x Line Volts x 1.732

1000

kW

= kVA x P.F

THREE PHASE AC MOTORS (415V AC)

Power
kW
0.75
1.1
1.5
2.2
3.0
4.0
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
150
160
185
200
220
250
315
355
400
450
500

Horse Power
HP
1.0
1.5
2.0
3.0
4.0
5.5
7.5
10
15
20
25
30
40
50
60
75
100
120
150
180
200
220
250
270
300
340
430
480
545
610
680

Full Load Current

A
1.9
2.5
3.5
5.0
6.5
8.0
11
14
21
28
35
40
55
66
80
102
135
165
200
230
260
280
325
350
385
450
545
580
650
740
820

Electric Motors
Power Output
kW Output

= Power Input x Efciency

= kW Input x Efciency

kW Output

= 1.732 x Line Volts x Line Amps x P.F x Efciency

1000

kVA Input

= 1.732 x Line Volts x Line Amps

1000

Line Current
(Input)

Line Current
(Input)

= 1000 x kVA Input

Line Volts x 1.732

1000 x kW Output
Line Volts x 1.732 x P.F x Efciency

Table 6.1
156

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157

PERMISSIBLE SHORT CIRCUIT TEMPERATURE

AND THE PROSPECTIVE FAULT LEVEL FOR
CABLES AND THEIR INSULATION
Based on the nal (permissible) short circuit temperature of a
fault duration of 1 sec, the values for calculating the prospective
fault are listed below.
Insulation

Permissible Rated
Operating
Temperature

Permissible Short
Circuit
Temperature

Conductor temperature at the beginning of the short

circuit in C

Silicone

180

350

PVC

75

150

Untinned
Conductor

90

250

Tinned
Conductor

90

200

EVA

125

250

126 135 143 148 154 159 165 170 176

Tinned
Conductor

200

49

65

79

91

102 112 122 128 136 141 147 153 159

Soldered
Joint

160

36

58

74

180 165 150 135 120 105

90

80

70

60

50

40

30

J thr for 1 sec in A/mm

132 139 146 153 160 166 173 178 182 187 191 196 201
-

- 109 117 124 131 138

EPR
143 148 154 159 165 170 176
122 128 135 141 147 153 159

87

100 107 115 122 129 136 143

Table 6.2

158

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159

Support for Vertically Suspended Cables

Formula for calculating the

fault level I thr of a cable
I thr
Example:

J thr x conductor size in mm2

A 4 x 25mm2 EPR/CSP fully loaded and
therefore having a continuous conductor
operating temperature of 90oC
I thr
=
143 x 25
=
3.58 kA for 1 second
For fault durations up to 5 sec or below 1 sec the following equation
is applicable (example is for 0.2 sec fault).
=
I(1
1 sec
=
I(1s) x
I thz
0.2 sec

The anchoring of cables is best achieved with a stress relief drum. The
open ended construction facilitates installation and replacement while
affording better stress relief and jacket protection than cable grips. At
least 2 1/2 cable turns should be wound around the drum. Refer to the
minimum Bending Radii data for each cable type to determine the
stress relief drum diameter.

Suggested stress relief drum design

Connection Point

Cable Suspension
The maximum free suspension height in metres for
reeling cables that must be vertically suspended shall be
calculated utilising the following.This formula protects the
copper conductors from deformation past their elastic limit.
Conductor deformation leads to cork screws and possible core
breakages.
Height

C x CSA x N
W x 9.8

C
CSA
N
W

=
=
=
=

Number of Conductors in the cable

Conductor Cross Section in mm2
Max. Tensile limit in N/mm2 of the cable
Cable Weight in kg/mtr

Example: Cordaex (K) 5 x 1.5 mm2

= 5 x 1.5 x 20
= 150
0.26 x 9.8
2.54

160

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Single
Clamp

Fixed
Mounting

59 mtrs
maximum
suspension
height

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Stress Relief
Drum

Cable

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161

CHEMICAL RESISTANCE OF DIFFERENT

Chemical

PCP
3.3kV Flex

Neoprene 1
Acetic acid
Benzene
Bitumous tar
Bleach (NaCLO2)
Coke oven gas
Diesel oil
Ethylene glycol
Gasoline
Hydraulic oil
Hydrochloric acid (21%)
Hydrogen sulphide
Kerosene
Methanol
Methyl ethyl keton
Nitric acid (10%)
Phosphoric acid (60%)
Picric acid (10%)
Potassium chloride
Sodium hydroxide (25%)
Sulphuric acid (50%)
Transformer oil
Trichlorethylene
Vegetable oils & fats
UV resistance
Ozone resistance
Water resistance
Tear & notch resistance
Low temp. exibility
Abrasion resistance

P
F
G
VG
VG
F
VG
G
VG
E
E
G
E
G
G
VG
E
E
E
E
G
P
VG
E
VG
E
VG
E
VG

PCP

CSP

Planoex
Ozoex
Protolon (SM)
Cordaex (SMK)
Protomont
Rondoex
Neoprene 2
Hypalon
P
F
G
VG
VG
F
VG
G
VG
E
E
G
E
G
G
VG
E
E
E
E
VG
P
VG
E
VG
E
E
VG
VG-E

Table 6.3
E = Excellent
VG = Very Good
The results tabled are generic for each particular sheath compound and
attack, temperature and contact contamination

CABLE SHEATH MATERIALS

F
F
G
VG
VG
VG
VG
G
VG
E
VG
G
E
G
E
E
E
E
E
E
G
P
VG
E
VG
E
G
VG
VG

CPE

PU

EPR

EVA

SI

PVCPU EPR

Mining MSR

Spreaderex

Hydrorm

EVA125

Sinotherm

Protoex
Pendantex

Chlorinated
Polyethylene
F
F
G
VG
VG
VG
VG
G
VG
E
E
G
E
G
E
E
E
E
E
E
VG
P
VG
E
VG
VG
VG
G
G-VG

Polyurethane

Ethylene
Propylene
P
P
P
E
VG
F
E
F
P
P
E
F
E
E
E
E
VG
E
E
E
F
P
VG
E
E
E
F-G
E
G

Ethylvinyl
Acetate
F
P
P
P
G
G
F
G
VG
F
G
G
P
P
P
P
F
E
P
P
G
P
G
VG
E
G
F
G
VG

Silicone

Polyvinyl
Chloride
P
F
G
VG
VG
VG
G
F
VG
VG
VG
F
G
P
VG
E
E
E
G
VG
VG
P
VG
G
E
G
VG
G
VG

G = Good

PCP Polychloroprene (Neoprene) CSP Chlorosulphonated Polyethylene (Hypalon) CPE Chlorinated

162

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F
P
G-VG
F
VG
VG
F
E
E
F
P
VG
F
G
F
G
F
E
P
P
E
F-P
E
E
E
F
E
E
E

VG
P
F
VG
F
P
E
P
E
P
P
P
E
P
P
E
P
E
P
P
P
P
E
VG
VG
E
P
E
P

F = Fair
P = Poor
should be used as such. For a more exact evaluation, the chemical concentration, duration of
should be known.
Polyethylene EPR Ethylene Propylene Rubber EVA Ethyl vinyl Acetate PVC Polyvinyl Chloride

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163

VOLT DROP

Formula 1 Actual Volts

Vd =
where

Vd =
L=
I=
mV/Am =

In accordance with AS 3000 the permissible volt drop from the point
of the connection is 5% of the supply voltage. The following tables
and formula should be used to satisfy volt drop limitations.

L x I x mV/Am
1000
volt drop in volts
route length of cable in metres
current to be carried in Amps
millivolt per ampere metre
value from Tables 6.4 and 6.5.

*With this method the drop in voltage (in volts) is given

and shall not exceed 5% of the supply voltage, i.e.,
5% of 415V = 20.75V.
Formula 2
mV/A.m value Vc
where

=
Vc =
Vd =
L=
I=

1000 x Vd
LxI
millivolts per Ampere metre
volt drop in volts
route length of cable in metres
current to be carried in Amps

* With this method the millivolts per ampere metre is given

and the appropriate conductor size shall be selected from
Tables 6.5 and 6.6. The conductor size selected shall be
nearest to, but not exceed the formula result,
e.g.,
415V, 3 phase installation,
load demand is 55A,
100m length: OZOFLEX
Result: 3.77mV/A.m 4 x 10mm2

164

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Three Phase Voltage Drop - Single Core Cables in Trefoil

Conductor

Three Phase Voltage Drop at 50Hz, mV/Am

Size

Conductor Temperature C
45C

mm2

Max.

60C
0.8pf

Max.

75C
0.8pf

Max.

90C
0.8pf

Max. 0.8pf

1.0

33.9

35.9

37.6

39.5

1.5

22.9

24.1

25.3

26.7

2.5

13.7

14.4

15.2

15.9

8.68

9.14

9.62

10.1

5.80

6.11

6.42

6.74

10

3.43

3.64

3.83

4.00

16

2.18

2.30

2.41

2.53

25

1.28

1.35

1.42

1.48

35

1.00

1.06

1.11

1.16

50

0.748

0.788

0.824

0.863

70

0.532

0.558

0.584

0.627

95

0.411

0.430

0.447

0.464

120

0.331

0.345

0.357

0.371

150

0.286

0.303

0.307

185

0.244

0.244

0.251

0.251

0.260

0.259

0.269 0.267

240

0.213

0.210

0.218

0.215

0.223

0.221

0.229 0.227

300

0.192

0.186

0.197

0.191

0.201

0.196

0.206 0.201

400

0.178

0.167

0.182

0.171

0.184

0.174

0.187 0.178

500

0.168

0.153

0.170

0.156

0.171

0.159

0.173 0.161

630

0.159

0.141

0.160

0.142

0.161

0.144

0.164 0.150

0.319

Table 6.4

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165

WIRING SYSTEMS IN HAZARDOUS AREAS

(Not applicable to coal mining areas)
Three Phase Voltage Drop - Multicore Cables
Conductor
Size

Class I

Three Phase Voltage Drop at 50Hz, mV/Am

Conductor Temperature C
45C

mm2

Max.

1.0
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630

33.4
23.2
14.0
8.85
5.91
3.52
2.22
1.30
1.01
0.759
0.533
0.438
0.324
0.274
0.234
0.196
0.175
0.161
0.145
0.138

0.8pf

0.196
0.175
0.154
0.136
0.124

60C
Max
0.8pf
36.5
24.4
14.7
9.32
6.24
3.69
2.32
1.37
1.07
0.797
0.559
0.424
0.339
0.284
0.242
0.201
0.180
0.164
0.147
0.139

0.201
0.178
0.158
0.139
0.126

75C
Max.
0.8pf
38.6
25.6
15.5
9.82
6.56
3.90
2.46
1.44
1.12
0.837
0.589
0.445
0.353
0.298
0.253
0.208
0.184
0.173
0.149
0.140

0.207
0.183
0.162
0.142
0.128

90C
Max. 0.8pf
40.4
29.0
16.2
10.3
6.88
4.07
2.58
1.51
1.18
0.875
0.613
0.464
0.367
0.308
0.260
0.213
0.197
0.189
0.151
0.142

Intrisically safe systems in

accordance with AS 2381.7

Cable in metallic conduit

Served MIMS

PVC, elastomer or silicone sheathed;

circular unarmoured
PVC, elastomer or silicone sheathed;
armoured

Cables in rigid and exible,

non-metallic conduit

0.213
0.188
0.165
0.145
0.131

Metal sheathed, served and armoured

Flexible cords and cables in

accordance with Clause 3.16.1 AS 2381.1 - 1991

Cables in corrugated non-metallic

conduit

Metal sheathed, served and

unarmoured

X
Table 6.6

X denotes acceptable use

Table 6.5

NOTE: The values in the tables are taken from AS 3008.1 and
based on cables operating at maximum conductor temperature. For
lightly loaded cables the standard also permits determination of the
appropriate Vd in such cases and therefore the tables list reduced
conductor temperatures.

166

Class II

Zone 0 Zone 1 Zone 2

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Clause 3.16.1 - AS2381.1-1991 states that the maximum length of

the exible cable shall be 600mm in Class 1 Zone 0 and Zone 1.
This table, extracted from the hazardous location standard AS2381.1,
nominates the allowable cable types for each Class and Zone
classication.
Fibre optic cables can be used in all areas without further protection.
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167

DE-RATING FOR PARALLEL CONNECTION

The following factors should be applied to conductors
connected in parallel for the various methods of installation.
Table taken from AS 3008.1.
Arrangement of Cables
1

De-rating Factors
No. of Circuits/Cables in parallel
8
9
10
12
14

16

18
-

1.

Bunched in air

1.00

0.87

0.75

0.72

0.70

0.67

2.

Bunched on a surface or
enclosed in conduit or
ducting

1.00

0.80

0.70

0.65

0.60

0.57

0.54

0.52

0.50

0.48

0.45

0.43

0.41

3.

Single
layer on
wall or oor

Touching

1.00

0.85

0.79

0.75

0.73

0.72

0.72

0.71

0.70

Spaced*

1.00

0.94

0.90

0.90

0.90

0.90

0.90

0.90

0.90

0.90

0.90

0.90

0.90

Touching

0.95

0.81

0.72

0.68

0.64

0.63

0.62

0.61

Spaced*

0.95

0.85

0.85

0.85

0.85

0.85

0.85

0.85

0.85

0.85

0.85

0.85

0.85

4.
5.

Single
layer under
ceiling

6.

20 or
more
-

0.39 0.38
-

0.90 0.90
-

0.85 0.85

Table 6.7

NOTE: De-rating is necessary for the purpose of thermal

dissipation.
If sufcient clearance from adjacent conductors/cables is
allowed for then no de-rating is necessary. To avoid de-rating
a minimum clearance of 2 x cable O.D for horizontal, and
4 x cable O.D for vertical installation in air are given
in AS 3008.1
* Spaced in the above table indicates a clearance of 1 x cable
O.D between adjacent cables.

168

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169

ATTENUATION DATA FOR CORDAFLEX AND

Attenuation Data
for Individually
Individually Screened Conductors
Screened
Frequency
Line Attenuation Impedance
Conductors
Hz
dB/1000ft
dB/km
Z
300
0.26
0.85
200
600
0.37
1.2
150
1200
0.52
1.7
110
2400
0.70
2.3
90
4800
0.98
3.2
60
9600
1.28
4.2
50
19200
1.52
5.0
40
38400
1.83
6.0
38
48000
1.92
6.3
35
57600
1.38
6.5
35
115200
2.44
8.0
35
153600
2.59
8.5
35

PLANOFLEX SCREENED CORES

Capacitance
pF/ft
nF/km
61.0
200.2
61.0
200.0
61.0
200.0
60.9
199.9
60.8
199.6
60.7
199.0
60.5
198.6
60.4
198.0
60.3
197.9
60.3
197.8
60.2
197.4
60.1
197.2

Inductance
mH/1000ft mH/km
0.08
0.256
0.08
0.256
0.08
0.256
0.08
0.256
0.08
0.256
0.08
0.256
0.08
0.256
0.08
0.251
0.08
0.249
0.08
0.248
0.07
0.238
0.07
0.235

Resistance
/1000ft
/km
15.2
50
15.2
50
15.2
50
15.2
50
15.2
50
15.2
50
15.2
50
15.8
52
16.5
54
16.8
55
19.2
63
20.4
67

Capacitance
pF/ft
nF/km
31.3
102.6
30.9
101.4
30.5
100.2
30.2
99.2
30.1
98.6
29.9
98.1
29.8
97.6
29.6
97.2
29.6
97.0
29.5
96.9
29.4
96.4
29.3
95.9

Inductance
mH/1000ft mH/km
0.21
0.69
0.21
0.69
0.21
0.69
0.20
0.67
0.20
0.66
0.20
0.65
0.19
0.61
0.17
0.56
0.16
0.54
0.16
0.52
0.14
0.47
0.14
0.46

Resistance
/1000ft
/km
7.9
26
7.9
26
7.9
26
7.9
26
7.9
26
9.1
30
11.0
36
14.6
48
15.8
52
17.1
56
23.8
78
26.8
88

Table 6.8

Attenuation Data
for Twisted
Twisted Screened Pairs
Screened Pair
Frequency
Line Attenuation Impedance
Conductors
Hz
dB/1000ft
dB/km
Z
300
0.13
0.42
250
600
0.18
0.60
200
1200
0.24
0.80
150
2400
0.30
1.0
130
4800
0.40
1.3
100
9600
0.46
1.5
90
19200
0.61
2.0
85
38400
0.85
2.8
80
48000
1.01
3.3
78
57600
1.07
3.5
75
115200
1.68
5.5
70
153600
1.74
5.7
70
Table 6.9

170

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171

DC AND AC RESISTANCE OF FLEXIBLE CABLES

Conductor
Size

mm2
0.5
0.75
1.0
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500

Single Core
Conductor Temperature C
DC resistance
/km
20C
38.2
25.4
19.1
13.0
7.82
4.85
3.32
1.93
1.18
0.710
0.521
0.391
0.258
0.202
0.156
0.123
0.101
0.0835
0.0613
0.0452
0.0373

AND CORDS WITH COPPER CONDUCTORS

Conductor
Size

AC resistance at 50 Hz, /km

60C
29.4
22.1
15.0
9.05
5.61
3.74
2.23
1.37
0.822
0.603
0.453
0.299
0.235
0.182
0.144
0.119
0.0928
0.0740
0.0565
0.0483

75C
30.9
23.2
15.8
9.51
5.90
3.93
2.35
1.44
0.864
0.634
0.476
0.314
0.246
0.191
0.151
0.125
0.0972
0.0775
0.0590
0.0503

90C
32.4
24.4
16.6
10.0
6.18
4.12
2.46
1.50
0.906
0.665
0.499
0.330
0.258
0.200
0.158
0.131
0.102
0.081
0.0615
0.0523

mm2
0.5
0.75
1.0
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500

Multicore
Conductor Temperature C
DC resistance
/km
20C
40.1
26.7
20.0
13.7
8.21
5.09
3.39
2.02
1.24
0.746
0.547
0.410
0.271
0.212
0.164
0.129
0.106
0.0877
0.0644
0.0475
0.0392

AC resistance at 50 Hz, /km

60C
45.1
30.9
23.1
15.9
9.50
5.89
3.92
2.34
1.44
0.864
0.633
0.475
0.315
0.247
0.191
0.151
0.125
0.0981
0.0787
0.0606
0.0522

75C
47.4
32.5
24.3
16.7
10.0
6.19
4.12
2.46
1.51
0.908
0.666
0.499
0.331
0.259
0.201
0.159
0.131
0.103
0.0824
0.0632
0.0542

90C
49.7
34.0
25.5
17.5
10.5
6.49
4.32
2.58
1.58
0.952
0.698
0.523
0.346
0.271
0.211
0.166
0.138
0.107
0.0860
0.0658
0.0563

Table 6.10

Table 6.10 lists measured values that conform to AS 3008.1

for rope laid exible cables. For cables with an alternate core
length of lay (e.g., CORDAFLEX) the values will alter slightly.

172

Technical Support Phone 03) 9721 7281

Sales Phone 131 773

Sales Phone 131 773

Technical Support Phone 03) 9721 7281

173