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About Voltage Drop

When electrical current moves through a wire, it is pushed by electrical potential (voltage) and it needs to surpass a certain level of contrary pressure caused by the wire. The voltage drop is the amount of electrical potential (voltage) loss caused by the contrary pressure of the wire. If the current is alternating, such contrary pressure is called impedance. Impedance is a vector, or two-dimensional quantity, consisting of resistance and reactance (reaction of a built-up electric field to a change of current). If the current is direct, the contrary pressure is called resistance.

Excessive voltage drop in a circuit can cause lights to flicker or burn dimly, heaters to heat poorly, and motors to run hotter than normal and burn out. It is recommended that the voltage drop should be less than 5% under a fully loaded condition. This can be achieved by selecting the right wire, and by taking care in the use of extension cords and similar devices.

Causes of Voltage Drop

There are four major causes of voltage drop:

• Wire Material: The choice of material used for the wire. Silver, copper, gold, and aluminum are among the metals with the best electrical conductivity. Copper and aluminum are the most common materials used for wires due to their relatively low price compared with silver and gold. Copper is a better conductor than aluminum and will have less voltage drop than aluminum for a given length and wire size.
• Wire Size: Larger wire sizes (those with a greater diameter) will have less voltage drop than smaller wire sizes of the same length. In American wire gauge, every 6-gauge decrease doubles the wire diameter, and every 3-gauge decrease doubles the wire cross sectional area. In the Metric Gauge scale, the gauge is 10 times the diameter in millimeters, so a 50 gauge metric wire would be 5 mm in diameter.
• Wire Length: Shorter wires will have less voltage drop than longer wires for the same wire size. Voltage drop becomes important when the length of a run of wire or cable becomes very long. Usually this is not a problem in circuits within a house, but may become an issue when running wire to an outbuilding, well pump, etc.
• Current Load: The amount of current being carried can affect voltage drop levels; an increase in current through a wire results in an increased voltage drop. Current carrying capacity is often referred to as ampacity, which is the maximum number of electrons that can be pushed at one time – the word ampacity is short for ampere capacity.

Voltage Drop Calculation

Ohm's Law is a very basic law for calculating voltage drop:

Vdrop = I·R

where:

• I: the current through the wire, measured in amperes
• R: the resistance of the wires, measured in ohms

The resistance of the wires is often measured and given as length-specific resistance, normally in the unit of ohms per kilometer or ohms per 1000 feet. Also, the wire is round-tripped. Therefore, the formula for a single-phase or direct current circuit becomes:

Vdrop = 2·I·R·L

The formula for a three-phase circuit becomes:

Vdrop = √3·I·R·L

where:

• I: the current through the wire
• R: the length-specific resistance of the wires
• L: the one-way length

Typical AWG Wire Sizes

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