Compliance Notice:
Voltage drop is the silent killer of electrical installations. A cable might be perfectly sized for current-carrying capacity under our AS/NZS 3008 Cable Size Calculator but still deliver under-voltage to the load if the run is too long. AS/NZS 3000 caps total voltage drop at 5% from the point of supply. Explore our full range of Electrician Calculators for complete on-site compliance.
What is Voltage Drop and Why Does it Matter?
Every cable has electrical resistance. When current flows through that resistance, voltage is lost as heat along the length of the conductor. The longer the cable run and the higher the current, the more voltage is lost before reaching the connected load.
On a 230V supply, 5% voltage drop means the load only sees 218.5V. If the street supply sits at 225V on a hot afternoon (common in regional or fringe grid areas), losing another 5% means the load receives only 213.75V. Motors overheat, compressors stall, and LED drivers flicker or fail prematurely.
AS/NZS 3000 Clause 3.6 establishes a strict 5% total limit from the point of supply to the furthest outlet.
Single-Phase vs Three-Phase Voltage Drop Formulas
The calculation differs based on phase configuration and return current paths:
- Single-Phase (230V): Current travels out on the active and returns on the neutral. Voltage drops across both conductors, effectively doubling route resistance. The formula incorporates a factor of 2:
V_drop = (2 × L × I × Rc) ÷ 1000 - Three-Phase (400V): In a balanced system, line-to-line voltage drop uses √3 (1.732) as the multiplier against 400V:
V_drop = (√3 × L × I × Rc) ÷ 1000
Three-phase systems experience lower percentage drops for equivalent load power because of the 400V denominator and 1.732 multiplier.
AS/NZS 3008 Conductor mV/A·m Unit Values (Copper 75°C)
Under AS/NZS 3008.1.1 Table 42, voltage drop calculations rely on millivolts dropped per ampere-metre of circuit route (mV/A·m). Single-phase values account for active + neutral loop length, while three-phase values reflect line-to-line drop:
| Conductor Size | Single-Phase (230V) mV/A·m | Three-Phase (400V) mV/A·m | Conductor DC Resistance @ 20°C |
|---|---|---|---|
| 1.5 mm² | 30.1 mV/A·m | 26.1 mV/A·m | 13.6 Ω/km |
| 2.5 mm² | 18.1 mV/A·m | 15.7 mV/A·m | 7.41 Ω/km |
| 4.0 mm² | 11.3 mV/A·m | 9.79 mV/A·m | 4.61 Ω/km |
| 6.0 mm² | 7.53 mV/A·m | 6.52 mV/A·m | 3.08 Ω/km |
| 10.0 mm² | 4.50 mV/A·m | 3.90 mV/A·m | 1.83 Ω/km |
| 16.0 mm² | 2.81 mV/A·m | 2.43 mV/A·m | 1.15 Ω/km |
| 25.0 mm² | 1.79 mV/A·m | 1.55 mV/A·m | 0.727 Ω/km |
| 35.0 mm² | 1.29 mV/A·m | 1.12 mV/A·m | 0.524 Ω/km |
Worked Example — 90m Shed Sub-Main Run
Consider running a sub-main 90 metres from a house main switchboard to a detached shed sub-board supplying a 32A single-phase load using 6 mm² TPS copper:
- Step 1 — Values: L = 90m, I = 32A, 6 mm² mV/A·m = 7.53 (AS/NZS 3008 loop rating).
- Step 2 — Calculation:
Drop = (7.53 × 32 × 90) ÷ 1000 = 21.69V - Step 3 — Drop Percentage:
(21.69V ÷ 230V) × 100 = 9.43%(Fails 5% limit significantly). - Step 4 — Upgrade Check: Trying 10 mm² yields 5.62% (still over). Upgrading to 16 mm² yields 3.53% drop (Complies ✓).
Single-Phase Max Route Lengths (5% Drop on 230V)
Maximum route lengths (in metres) to maintain ≤ 5% voltage drop (11.5V) for standard 230V V-90 PVC copper runs:
| Cable Size | 10A Load | 16A Load | 20A Load | 25A Load | 32A Load |
|---|---|---|---|---|---|
| 1.5 mm² | 40 m | 25 m | 20 m | — | — |
| 2.5 mm² | 67 m | 42 m | 33 m | 27 m | — |
| 4 mm² | 107 m | 67 m | 53 m | 43 m | 33 m |
| 6 mm² | 160 m | 100 m | 80 m | 64 m | 50 m |
| 10 mm² | 267 m | 167 m | 133 m | 107 m | 83 m |
| 16 mm² | 427 m | 267 m | 213 m | 171 m | 133 m |
Three-Phase Max Route Lengths (5% Drop on 400V)
Maximum route lengths (in metres) to maintain ≤ 5% line-to-line voltage drop (20.0V) on balanced 400V three-phase commercial circuits:
| Cable Size | 16A 3-Phase | 25A 3-Phase | 32A 3-Phase | 40A 3-Phase | 50A 3-Phase | 63A 3-Phase |
|---|---|---|---|---|---|---|
| 2.5 mm² | 80 m | 51 m | 40 m | 32 m | — | — |
| 4.0 mm² | 128 m | 82 m | 64 m | 51 m | 41 m | — |
| 6.0 mm² | 192 m | 123 m | 96 m | 77 m | 61 m | 49 m |
| 10.0 mm² | 320 m | 205 m | 160 m | 128 m | 102 m | 81 m |
| 16.0 mm² | 514 m | 329 m | 257 m | 206 m | 164 m | 131 m |
| 25.0 mm² | 806 m | 516 m | 403 m | 322 m | 258 m | 205 m |
When Voltage Drop Controls Cable Size
On runs under 20 metres, current-carrying capacity dictates cable selection. On runs exceeding 30 metres for sub-mains or 40 metres for final sub-circuits, voltage drop becomes the controlling constraint. Also verify physical enclosure limits with our Conduit Fill Calculator.
Voltage Drop in Three-Phase Motor Circuits & Worked Math
Direct-on-line (DOL) electric motors draw 6 to 8 times their rated full-load current (FLA) during starting. While running drop must remain ≤ 5%, transient starting drop must not exceed distributor limits (typically 10%–15%) to prevent contactor chattering:
Worked Scenario: 15 kW 400V Industrial Workshop Compressor
Load Details: 15 kW motor, 400V 3-phase, 27.5A running current (FLA), power factor 0.85, route distance 65 metres in PVC conduit.
Running Check on 6 mm² (mV/A·m = 6.52):
V_drop = (6.52 × 27.5A × 65m) ÷ 1000 = 11.65V
Drop % = (11.65V ÷ 400V) × 100 = 2.91% (≤ 5.0% ✓ Pass).
DOL Starting Surge Check (6× Current = 165A):
V_start = (6.52 × 165A × 65m) ÷ 1000 = 69.9V (17.5% drop — Excessive line dip!)
Rectification: Upgrade feeder cable to 16 mm² (mV/A·m = 2.43). Under starting surge, V_start = (2.43 × 165 × 65) ÷ 1000 = 26.0V (6.5% dip — Safe for industrial switchboards ✓).