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Calculation No.: Calc-001
Revision: A
Description:
Created By: Engineer Name
Project: Project Name
Project No.: P001
Client: Client Name

Motor Cable Selection Chart

A selection chart for one installation condition: rows are preferred motor ratings with their automatically selected protective device, columns are conductor sizes with their derated current-carrying capacity I_Z. Each cell is the longest cable run the motor may be supplied over, the smallest of three lengths: the running voltage drop, the starting voltage dip and the earth fault loop impedance that still lets the device disconnect. Cable data per AS/NZS 3008.1.1:2017; disconnection and earth conductor size per AS/NZS 3000:2018 Appendix B5 and Table 5.1. Grey cells are not applicable (cable rating below the design current, no device rating, or a size not tabulated); yellow cells are governed by the earth fault loop or sit in a column whose size fails the short-circuit or earth-conductor checks; red column headers mark those failing sizes.

1.1 Supply & Motor Basis

Supply, motor and voltage-drop basis common to every row:
Parameter Symbol Value Notes
AS/NZS 3008 Edition 2017 The only supported edition
Power Factor Direction lagging Sign of the reactive voltage-drop term
Supply Voltage V 400 V Line-to-line, three phase
Power Factor cosφ 0.85 Running, full load
Motor Efficiency η 95 % IEC 60072 ratings are shaft output
Starting Method DOL
Starting Current Multiple kstart 6 × I<sub>FL</sub> Used for DOL
Starting Power Factor cosφstart 0.35
Design Factor kdesign 1.25 I<sub>B</sub> = k<sub>design</sub> × I<sub>FL</sub>
Maximum Running Voltage Drop Vd,max 5 %
Maximum Starting Voltage Dip Vd,start 15 %

1.2 Cable

Cable construction; the conductor size varies by column:
Parameter Symbol Value Notes
Cable Type Fixed Cable construction
Cable Formation Multicore Multicore or Singlecore
MC Arrangement Circular Conductor arrangement
Cable Insulation XLPE Insulation type
Conductor Material Material Cu Cu or Al
Earth Conductor AS/NZS 3000 Table 5.1 minimum Per column; shown under each size
Resistance Temperature θR 90 °C Conductor operating temperature for R<sub>c</sub>

1.3 Installation

Installation method and environmental conditions:
Parameter Symbol Value Notes
Installation Method Unenclosed
Unenclosed Type (MC) Spaced from Surface
Air Arrangement Perforated Trays Horizontal
Cables Per Tier 1
Ladder Spacing Spaced
Ladder Tiers 1Tier
Air Ambient Temp 40
Cables per Tier 1
Derating Table D24 AS/NZS 3008.1.1:2017

1.4 Protection

Device type, trip multiplier, fault level and clearing times:
Parameter Symbol Value Notes
Device Type gM Rating auto-selected per row: smallest standard I_N ≥ I_B
Instantaneous Trip Multiplier kmag 5 × I<sub>N</sub> Disconnection current I<sub>a</sub> = k<sub>mag</sub> × I<sub>N</sub>
Prospective Fault Current If 10 kA
Protection Clearing Time tprot 100 ms Short-circuit withstand
Earth Fault Clearing Time tef 40 ms Near-end earth fault (earth withstand)
Source Impedance Zs 100 mΩ Upstream loop impedance

1.5 Chart Extents

Motor ratings and conductor sizes covered by the chart:
Parameter Symbol Value Notes
Motor Range 0.37 – 185 24 preferred ratings
Conductor Range 2.5 – 185 14 columns incl. parallel
Parallel Sizes 95 2 cables in parallel
Display Cap Lcap 500 m Longer lengths shown as "> cap"

2. Method

Every cell is worked from the motor rating and the per-size cable data. Lengths are in metres; R and X are AS/NZS 3008.1.1 per-kilometre values (already divided by the number of cables for parallel columns). Resistances are read at the insulation operating temperature (PVC 75 °C, XLPE 90 °C, EPR 110 °C; aluminium capped at 90 °C).

2.1 Full Load Current

Line current of a three-phase motor of shaft output P (kW):

Formula: $$ I_{FL} = \frac{P \times 1000}{\sqrt{3} \, V \cos\varphi \, \eta} $$

2.2 Starting Current

k_start from the starting method unless overridden.

Formula: $$ I_{start} = k_{start} \times I_{FL} $$

2.3 Design Current and Device

I_N is the smallest standard device rating not less than the design current.

Formula: $$ \begin{aligned} I_B &= k_{design} \times I_{FL} \qquad I_N \\ &= \min\{ I_{N,std} \geq I_B \} \end{aligned} $$

2.4 Disconnection Current

Earth-fault current that must flow for automatic disconnection (AS/NZS 3000:2018 B5).

Formula: $$ I_a = k_{mag} \times I_N $$

2.5 Running Voltage-Drop Length

Formula: $$ L_{run} = \frac{V_{d,max}/100 \times V}{\sqrt{3} \, I_{FL} \, \left| R_c \cos\varphi + X_c \sin\varphi \right|} \times 1000 $$

2.6 Starting Voltage-Dip Length

Same as the running length with the starting current, starting power factor and starting dip limit.

Formula: $$ L_{start} = \frac{V_{d,start}/100 \times V}{\sqrt{3} \, I_{start} \, \left| R_c \cos\varphi_{s} + X_c \sin\varphi_{s} \right|} \times 1000 $$

2.7 Earth Fault Loop Length

V_ph = V/√3; |Z_c| = √(R_c² + X_c²) and |Z_e| = √(R_e² + X_e²) in Ω/km. Magnitudes are added arithmetically, an upper bound on the phasor sum.

Formula: $$ L_{efl} = \frac{V_{ph}/I_a - Z_s}{|Z_c| + |Z_e|} \times 1000 $$

2.8 Cable Loading

A cell is blank when the loading exceeds 100 % (cable rating below I_B) or no device rating fits.

Formula: $$ \text{loading} = \frac{I_B}{I_Z} \times 100 \; \% $$

2.9 Maximum Length

The argument of the minimum is the governing limit; a cell is shaded yellow when the earth fault loop governs or the size fails a length-independent check.

Formula: $$ L = \min(L_{run}, L_{start}, L_{efl}) $$

2.10 Worked Cell

The first usable cell of the chart, a 0.37 kW motor on 2.5 mm² (row 1, column 1): I_FL 0.7 A, I_start 4.0 A, I_N 6 A, I_a 30 A; R_c 9.450, X_c 0.09880, R_e 9.450, X_e 0.09880 Ω/km.

2.11 Running Voltage-Drop Length

Formula: $$ \begin{aligned} L_{run} &= \frac{5/100 \times 400}{\sqrt{3} \times 0.6614 \times |9.450 \times 0.85 + 0.09880 \times 0.5268|} \times 1000 \\ &= 2160 \; \text{m} \end{aligned} $$

2.12 Starting Voltage-Dip Length

Formula: $$ \begin{aligned} L_{start} &= \frac{15/100 \times 400}{\sqrt{3} \times 3.97 \times |9.450 \times 0.35 + 0.09880 \times 0.9367|} \times 1000 \\ &= 2568 \; \text{m} \end{aligned} $$

2.13 Earth Fault Loop Length

Formula: $$ \begin{aligned} L_{efl} &= \frac{231/30.0 - 0.10000}{9.451 + 9.451} \times 1000 \\ &= 402 \; \text{m} \end{aligned} $$

2.14 Maximum Length

Governed by EFL. Loading I_B / I_Z = 3 %.

Formula: $$ \begin{aligned} L &= \min(2160, 2568, 402) \\ &= 402 \; \text{m} \end{aligned} $$

3. Cable Data per Size

Derated capacity, impedances, adiabatic k and the length-independent checks for each column (SC = short-circuit withstand, ESZ = earth conductor size, EWT = earth conductor withstand). Parallel columns carry n × I_Z and R, X divided by n.
Parameter Symbol Value Notes
2.5 mm² IZ 27.0 earth 2.5 mm², Rc 9.450 / Xc 0.099 Ω/km (earth Re 9.450 / Xe 0.099), F 1.000, k 143, SC FAIL · ESZ PASS · EWT FAIL
4 mm² IZ 36.0 earth 2.5 mm², Rc 5.880 / Xc 0.093 Ω/km (earth Re 9.450 / Xe 0.099), F 1.000, k 143, SC FAIL · ESZ PASS · EWT FAIL
6 mm² IZ 46.0 earth 2.5 mm², Rc 3.930 / Xc 0.089 Ω/km (earth Re 9.450 / Xe 0.099), F 1.000, k 143, SC FAIL · ESZ PASS · EWT FAIL
10 mm² IZ 66.0 earth 4 mm², Rc 2.330 / Xc 0.084 Ω/km (earth Re 5.880 / Xe 0.093), F 1.000, k 143, SC FAIL · ESZ PASS · EWT PASS
16 mm² IZ 87.0 earth 6 mm², Rc 1.470 / Xc 0.081 Ω/km (earth Re 3.930 / Xe 0.089), F 1.000, k 143, SC FAIL · ESZ PASS · EWT PASS
Parameter Symbol Value Notes
25 mm² IZ 116.0 earth 6 mm², Rc 0.927 / Xc 0.081 Ω/km (earth Re 3.930 / Xe 0.089), F 1.000, k 143, SC PASS · ESZ PASS · EWT PASS
35 mm² IZ 144.0 earth 10 mm², Rc 0.669 / Xc 0.079 Ω/km (earth Re 2.330 / Xe 0.084), F 1.000, k 143, SC PASS · ESZ PASS · EWT PASS
50 mm² IZ 182.0 earth 16 mm², Rc 0.494 / Xc 0.075 Ω/km (earth Re 1.470 / Xe 0.081), F 1.000, k 143, SC PASS · ESZ PASS · EWT PASS
70 mm² IZ 230.0 earth 25 mm², Rc 0.343 / Xc 0.074 Ω/km (earth Re 0.927 / Xe 0.081), F 1.000, k 143, SC PASS · ESZ PASS · EWT PASS
95 mm² IZ 275.0 earth 25 mm², Rc 0.248 / Xc 0.072 Ω/km (earth Re 0.927 / Xe 0.081), F 1.000, k 143, SC PASS · ESZ PASS · EWT PASS
Parameter Symbol Value Notes
120 mm² IZ 327.0 earth 35 mm², Rc 0.197 / Xc 0.071 Ω/km (earth Re 0.669 / Xe 0.079), F 1.000, k 143, SC PASS · ESZ PASS · EWT PASS
150 mm² IZ 375.0 earth 50 mm², Rc 0.160 / Xc 0.072 Ω/km (earth Re 0.494 / Xe 0.075), F 1.000, k 143, SC PASS · ESZ PASS · EWT PASS
185 mm² IZ 428.0 earth 70 mm², Rc 0.129 / Xc 0.072 Ω/km (earth Re 0.343 / Xe 0.074), F 1.000, k 143, SC PASS · ESZ PASS · EWT PASS
2 × 95 mm² IZ 550.0 earth 25 mm², Rc 0.124 / Xc 0.036 Ω/km (earth Re 0.464 / Xe 0.040), F 1.000, k 143, SC PASS · ESZ PASS · EWT PASS

4. Motor Data per Rating

Full load, starting and design currents with the selected device and its disconnection current:
Parameter Symbol Value Notes
0.37 kW IFL 0.7 I_start 4.0 A, I_B 0.8 A, I_N 6 A, I_a 30 A
0.55 kW IFL 1.0 I_start 5.9 A, I_B 1.2 A, I_N 6 A, I_a 30 A
0.75 kW IFL 1.3 I_start 8.0 A, I_B 1.7 A, I_N 6 A, I_a 30 A
1.1 kW IFL 2.0 I_start 11.8 A, I_B 2.5 A, I_N 6 A, I_a 30 A
1.5 kW IFL 2.7 I_start 16.1 A, I_B 3.4 A, I_N 6 A, I_a 30 A
Parameter Symbol Value Notes
2.2 kW IFL 3.9 I_start 23.6 A, I_B 4.9 A, I_N 6 A, I_a 30 A
3 kW IFL 5.4 I_start 32.2 A, I_B 6.7 A, I_N 10 A, I_a 50 A
4 kW IFL 7.1 I_start 42.9 A, I_B 8.9 A, I_N 10 A, I_a 50 A
5.5 kW IFL 9.8 I_start 59.0 A, I_B 12.3 A, I_N 13 A, I_a 65 A
7.5 kW IFL 13.4 I_start 80.4 A, I_B 16.8 A, I_N 20 A, I_a 100 A
Parameter Symbol Value Notes
11 kW IFL 19.7 I_start 118.0 A, I_B 24.6 A, I_N 25 A, I_a 125 A
15 kW IFL 26.8 I_start 160.9 A, I_B 33.5 A, I_N 40 A, I_a 200 A
18.5 kW IFL 33.1 I_start 198.4 A, I_B 41.3 A, I_N 50 A, I_a 250 A
22 kW IFL 39.3 I_start 235.9 A, I_B 49.2 A, I_N 50 A, I_a 250 A
30 kW IFL 53.6 I_start 321.7 A, I_B 67.0 A, I_N 80 A, I_a 400 A
Parameter Symbol Value Notes
37 kW IFL 66.1 I_start 396.8 A, I_B 82.7 A, I_N 100 A, I_a 500 A
45 kW IFL 80.4 I_start 482.6 A, I_B 100.5 A, I_N 125 A, I_a 625 A
55 kW IFL 98.3 I_start 589.9 A, I_B 122.9 A, I_N 125 A, I_a 625 A
75 kW IFL 134.1 I_start 804.4 A, I_B 167.6 A, I_N 200 A, I_a 1,000 A
90 kW IFL 160.9 I_start 965.2 A, I_B 201.1 A, I_N 250 A, I_a 1,250 A
Parameter Symbol Value Notes
110 kW IFL 196.6 I_start 1,179.7 A, I_B 245.8 A, I_N 250 A, I_a 1,250 A
132 kW IFL 235.9 I_start 1,415.7 A, I_B 294.9 A, I_N 315 A, I_a 1,575 A
160 kW IFL 286.0 I_start 1,716.0 A, I_B 357.5 A, I_N 400 A, I_a 2,000 A
185 kW IFL 330.7 I_start 1,984.1 A, I_B 413.4 A, I_N 500 A, I_a 2,500 A
Motor (kW)gM (A) 2.546101625355070951201501852 × 95
27 A36 A46 A66 A87 A116 A144 A182 A230 A275 A327 A375 A428 A550 A
0.376 402496> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500
0.556 402496> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500
0.756 402496> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500
1.16 402496> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500
1.56 402496> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500
2.26 363496> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500
310 239295338> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500
410 200295338> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500
5.513 145225258420> 500> 500> 500> 500> 500> 500> 500> 500> 500> 500
7.520 107144165269409454> 500> 500> 500> 500> 500> 500> 500> 500
1125 73114131213323359> 500> 500> 500> 500> 500> 500> 500> 500
1540 6979128195217351> 500> 500> 500> 500> 500> 500> 500
18.550 62100152169274418> 500> 500> 500> 500> 500> 500
2250 100152169274418> 500> 500> 500> 500> 500> 500
3080 8898159242373402> 500> 500> 500> 500
37100 6774120184282304410> 500> 500> 500
45125 5590137210227305399> 500453
55125 90137210227305399> 500453
75200 66102110148194263220
90250 667196126170143
110250 7196126170143
132315 53699478
160400 233126
185500 00

Maximum length = min(running Vd, starting Vd, earth fault loop) in metres; hover a cell for all three. Cu XLPE Multicore Fixed; Unenclosed (derating table D24); 400 V, cosφ 0.85, η 95 %; Vd 5 % running / 15 % starting; gM k_mag 5, Z_s 0.1 Ω.

  • not applicable (cable rating below I_B, no device, or untabulated)
  • earth-fault loop governs or size fails SC/earth checks
  • size fails a length-independent check
  • > 500 = beyond display cap
Motor (kW)gM (A) 2.546101625355070951201501852 × 95
27 A36 A46 A66 A87 A116 A144 A182 A230 A275 A327 A375 A428 A550 A
0.376 32211110000000
0.556 53321111100000
0.756 65432111111000
1.16 97543221111110
1.56 129754322111111
2.26 18141176433222111
310 251915108654322221
410 3325191410865433222
5.513 46342719141197544332
7.520 624736251914129765443
1125 91685337282117141198764
1540 12493735139292318151210986
18.550 15311590634836292318151311108
2250 182137107745742342721181513119
3080 24818614610277584737292420181612
37100 30623018012595715745363025221915
45125 372279219152116877055443731272318
55125 4553412671861411068568534538332922
75200 62146536425419314411692736151453930
90250 745559437305231173140110877361544737
110250 9106835343722832121711351078975665745
132315 109281964144733925420516212810790796954
160400 1324993777542411308248196155130109958465
185500 153111488996264753562872271801501261109775

Loading = I_B / I_Z × 100 % with I_B = k_design × I_FL. Cu XLPE Multicore Fixed; Unenclosed (derating table D24); 400 V, cosφ 0.85, η 95 %; Vd 5 % running / 15 % starting; gM k_mag 5, Z_s 0.1 Ω.

  • loading above 100 % (cable rating below I_B), no device, or untabulated
  • size fails a length-independent check

7. Size Checks

Short-circuit withstand (adiabatic, AS/NZS 3008 Table 52), AS/NZS 3000 Table 5.1 earth size and earth conductor withstand for each available size. These do not depend on length.
Parameter Symbol Value Notes
2.5 mm² FAIL SC: t_max 0.001 s vs t 0.1 s, S_min 22.1 mm² — FAIL; ESZ: earth 2.5 vs Table 5.1 minimum 2.5 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — FAIL (fails: Short Circuit, Earth Conductor Withstand)
4 mm² FAIL SC: t_max 0.003 s vs t 0.1 s, S_min 22.1 mm² — FAIL; ESZ: earth 2.5 vs Table 5.1 minimum 2.5 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — FAIL (fails: Short Circuit, Earth Conductor Withstand)
6 mm² FAIL SC: t_max 0.007 s vs t 0.1 s, S_min 22.1 mm² — FAIL; ESZ: earth 2.5 vs Table 5.1 minimum 2.5 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — FAIL (fails: Short Circuit, Earth Conductor Withstand)
10 mm² FAIL SC: t_max 0.020 s vs t 0.1 s, S_min 22.1 mm² — FAIL; ESZ: earth 4 vs Table 5.1 minimum 4 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — PASS (fails: Short Circuit)
16 mm² FAIL SC: t_max 0.052 s vs t 0.1 s, S_min 22.1 mm² — FAIL; ESZ: earth 6 vs Table 5.1 minimum 6 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — PASS (fails: Short Circuit)
Parameter Symbol Value Notes
25 mm² PASS SC: t_max 0.128 s vs t 0.1 s, S_min 22.1 mm² — PASS; ESZ: earth 6 vs Table 5.1 minimum 6 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — PASS
35 mm² PASS SC: t_max 0.251 s vs t 0.1 s, S_min 22.1 mm² — PASS; ESZ: earth 10 vs Table 5.1 minimum 10 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — PASS
50 mm² PASS SC: t_max 0.511 s vs t 0.1 s, S_min 22.1 mm² — PASS; ESZ: earth 16 vs Table 5.1 minimum 16 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — PASS
70 mm² PASS SC: t_max 1.002 s vs t 0.1 s, S_min 22.1 mm² — PASS; ESZ: earth 25 vs Table 5.1 minimum 25 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — PASS
95 mm² PASS SC: t_max 1.846 s vs t 0.1 s, S_min 22.1 mm² — PASS; ESZ: earth 25 vs Table 5.1 minimum 25 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — PASS
Parameter Symbol Value Notes
120 mm² PASS SC: t_max 2.945 s vs t 0.1 s, S_min 22.1 mm² — PASS; ESZ: earth 35 vs Table 5.1 minimum 35 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — PASS
150 mm² PASS SC: t_max 4.601 s vs t 0.1 s, S_min 22.1 mm² — PASS; ESZ: earth 50 vs Table 5.1 minimum 50 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — PASS
185 mm² PASS SC: t_max 6.999 s vs t 0.1 s, S_min 22.1 mm² — PASS; ESZ: earth 70 vs Table 5.1 minimum 70 mm² — PASS; EWT: S_min 3.23 mm² at I_ef 2,309 A, t_ef 0.04 s — PASS
2 × 95 mm² PASS SC: t_max 7.382 s vs t 0.1 s, S_min 11.1 mm² — PASS; ESZ: earth 25 vs Table 5.1 minimum 25 mm² — PASS; EWT: S_min 1.61 mm² at I_ef 1,155 A, t_ef 0.04 s — PASS

8. Summary

Chart coverage and governing limits:
Parameter Symbol Value Notes
Chart Size 24 × 14 motor ratings × size columns
Motor Range 0.37 – 185
Conductor Range 2.5 – 185 parallel: 95
Sizes Available 14 of 14 tabulated for this installation
Usable Cells 254 of 336 240 flagged, 148 beyond the display cap
Governing Limit run 5 · start 14 · EFL 235 usable cells by governing limit
Sizes Failing Checks 2.5, 4, 6, 10, 16 short circuit / earth size / earth withstand
Overall Status PASS PASS when at least one cell is usable

9. Warnings & Recommendations

Warnings: Sizes failing a length-independent check (flagged across the column): 2.5 mm² (Short Circuit, Earth Conductor Withstand); 4 mm² (Short Circuit, Earth Conductor Withstand); 6 mm² (Short Circuit, Earth Conductor Withstand); 10 mm² (Short Circuit); 16 mm² (Short Circuit) Parallel columns assume identical cables sharing the load current, the prospective fault and the earth-fault current equally, with no grouping derating beyond the installation entered: confirm the grouping of the parallel cables separately The earth fault loop governs 235 of 254 usable cells The upstream loop impedance (0.1 Ω) alone limits the earth-fault current to 2309 A, below the disconnection current of 185 kW (2500 A): those rows have no permissible length on the earth fault loop Recommendations: A larger earth conductor (earth sized as the phase), a lower disconnection multiple or an RCD lengthens the earth-fault-limited runs A lower disconnection multiple (an MCCB with adjustable instantaneous trip) or an RCD is needed for automatic disconnection of the largest motors

10. Standards

Cable current ratings, derating, impedances and k factors: AS/NZS 3008.1.1:2017. Disconnection by the earth fault loop, overload coordination and protective earth sizing: AS/NZS 3000:2018 (Appendix B5, Clause 2.5.3.1, Table 5.1). Preferred motor ratings per IEC 60072; preferred device ratings per AS/NZS 60898, AS/NZS 60947.2 and AS 60269.

Approval:

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Checked
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Date: ..........................
Approved
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