The formula is Ohm's law, V = I × R, with the resistance worked out for the actual length of wire in the circuit. Everything else is bookkeeping.
| Size | Uncoated copper | Aluminum |
|---|---|---|
| 14 | 3.14 | — |
| 12 | 1.98 | 3.25 |
| 10 | 1.24 | 2.04 |
| 8 | 0.778 | 1.28 |
| 6 | 0.491 | 0.808 |
| 4 | 0.308 | 0.508 |
| 3 | 0.245 | 0.403 |
| 2 | 0.194 | 0.319 |
| 1 | 0.154 | 0.253 |
| 1/0 | 0.122 | 0.201 |
| 2/0 | 0.0967 | 0.159 |
| 3/0 | 0.0766 | 0.126 |
| 4/0 | 0.0608 | 0.1 |
| 250 kcmil | 0.0515 | 0.0847 |
| 350 kcmil | 0.0367 | 0.0605 |
| 500 kcmil | 0.0258 | 0.0424 |
A 20 amp kitchen circuit run 100 feet from the panel, carrying a full 20 A load.
VD = 2 × 20 × 1.98 × 100 ÷ 1000
VD = 2 × 20 × 0.198 = 7.92 volts
Percentage = 7.92 ÷ 120 × 100 = 6.6%
Fails the 3% recommendation badly. Upsize to 10 AWG (4.96 V, 4.1%) or 8 AWG (3.11 V, 2.6%). At 120 V, long runs are punishing — the same circuit at 240 V would be at 3.3%.
An electric range on a 50 A double-pole breaker, 60 feet of 6 AWG copper.
VD = 2 × 50 × 0.491 × 60 ÷ 1000
VD = 2 × 50 × 0.02946 = 2.95 volts
Percentage = 2.95 ÷ 240 × 100 = 1.2%
Comfortably within the 3% recommendation. No upsizing needed.
A feeder to a detached garage, 150 feet one way, carrying a calculated 80 A load.
VD = 2 × 80 × 0.245 × 150 ÷ 1000
VD = 2 × 80 × 0.03675 = 5.88 volts
Percentage = 5.88 ÷ 240 × 100 = 2.5%
Within the 5% feeder-plus-branch allowance with 2.5% left for the branch circuits inside the garage. Note that upsizing here would also require upsizing the equipment grounding conductor under NEC 250.122(B).
A 65 A three-phase motor load 400 feet from the distribution panel.
VD = 1.732 × 65 × 0.194 × 400 ÷ 1000
VD = 1.732 × 65 × 0.0776 = 8.74 volts
Percentage = 8.74 ÷ 480 × 100 = 1.8%
Within 3%. Higher voltages carry the same power at lower current, which is exactly why long runs are done at 480 V rather than 240 V.
Most real problems are not "what is the drop" but "how big a wire do I need" or "how far can I run this". Solve for the term you want:
R = (VD × 1000) ÷ (2 × I × L)
Maximum allowable resistance per 1000 feet. Look up the first conductor in the table above with a resistance at or below this figure.
L = (VD × 1000) ÷ (2 × I × R)
Maximum one-way run for a given conductor. This is what the distance charts tabulate.
VDmax = Vnominal × 0.03
The 3% branch-circuit target: 3.6 V at 120 V, 7.2 V at 240 V, 14.4 V at 480 V.
Worked backwards: a 30 A circuit at 240 V running 200 feet. Allowable drop at 3% is 7.2 V. R = (7.2 × 1000) ÷ (2 × 30 × 200) = 0.60 ohms per 1000 feet. The first copper conductor at or below 0.60 is 6 AWG at 0.491. So a 30 A circuit that only needs 10 AWG for ampacity needs 6 AWG at 200 feet.
Voltage drop appears in the NEC as Informational Notes, not as enforceable rules, in 210.19(A) for branch circuits and 215.2(A) for feeders. The guidance is 3% maximum on the branch circuit and 5% maximum for the feeder and branch circuit combined.
Informational Notes are explicitly not enforceable under NEC 90.5(C), so an inspector cannot fail an installation for a 4% drop on that basis alone. Several other articles do make it mandatory in specific cases — 647.4(D) for sensitive electronic equipment, 695.7 for fire pump feeders, and Article 680 for some pool equipment.
What excessive drop actually costs you: incandescent lamps dim noticeably and lose far more light output than the voltage lost; motors draw higher current at lower voltage and run hotter, shortening their life; electronics with switching supplies compensate by drawing more current, which makes the drop worse; and every volt dropped is power turned into heat inside your walls.
Our calculator applies this formula along with NEC Table 310.16 ampacity and the 240.4(D) small-conductor limits, and returns the larger of the two requirements.
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