AS/NZS 3000 Clause 3.6

Voltage Drop Calculator Australia

Check single-phase (230V) and three-phase (400V) voltage drop against the mandatory 5% limit in AS/NZS 3000. Uses conductor resistance data from AS/NZS 3008.

Voltage Drop Calculator

Calculator Inputs

Phase Configuration
Design current of circuit
One-way distance to load
Range: 0.5 to 1.0 (default 0.9)
Allowable Drop Limit
5% is standard under AS/NZS 3000 Clause 3.6

AS/NZS 3000 Voltage Drop Guide & Technical Formula

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 SizeSingle-Phase (230V) mV/A·mThree-Phase (400V) mV/A·mConductor DC Resistance @ 20°C
1.5 mm²30.1 mV/A·m26.1 mV/A·m13.6 Ω/km
2.5 mm²18.1 mV/A·m15.7 mV/A·m7.41 Ω/km
4.0 mm²11.3 mV/A·m9.79 mV/A·m4.61 Ω/km
6.0 mm²7.53 mV/A·m6.52 mV/A·m3.08 Ω/km
10.0 mm²4.50 mV/A·m3.90 mV/A·m1.83 Ω/km
16.0 mm²2.81 mV/A·m2.43 mV/A·m1.15 Ω/km
25.0 mm²1.79 mV/A·m1.55 mV/A·m0.727 Ω/km
35.0 mm²1.29 mV/A·m1.12 mV/A·m0.524 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:

  1. Step 1 — Values: L = 90m, I = 32A, 6 mm² mV/A·m = 7.53 (AS/NZS 3008 loop rating).
  2. Step 2 — Calculation: Drop = (7.53 × 32 × 90) ÷ 1000 = 21.69V
  3. Step 3 — Drop Percentage: (21.69V ÷ 230V) × 100 = 9.43% (Fails 5% limit significantly).
  4. 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 Size10A Load16A Load20A Load25A Load32A Load
1.5 mm²40 m25 m20 m——
2.5 mm²67 m42 m33 m27 m—
4 mm²107 m67 m53 m43 m33 m
6 mm²160 m100 m80 m64 m50 m
10 mm²267 m167 m133 m107 m83 m
16 mm²427 m267 m213 m171 m133 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 Size16A 3-Phase25A 3-Phase32A 3-Phase40A 3-Phase50A 3-Phase63A 3-Phase
2.5 mm²80 m51 m40 m32 m——
4.0 mm²128 m82 m64 m51 m41 m—
6.0 mm²192 m123 m96 m77 m61 m49 m
10.0 mm²320 m205 m160 m128 m102 m81 m
16.0 mm²514 m329 m257 m206 m164 m131 m
25.0 mm²806 m516 m403 m322 m258 m205 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 ✓).

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