Wire

Wire
Low voltage power systems often operate at rather high Pl
asti
c Insul
ati
on Copper Conductor
current levels. Ifthe interconnectingcables are too small,
a large proportion ofthe power available will be wastedin
the cable itself. This loss can be reducedbyusinga larger
cable,but this increases costs. The acceptable maximum
voltage drop for DC loads is 5% of nominal battery
voltage. The chart and the formula on this page are
providedto help you in selectingthe best cost /power loss
compromise.
All the methods ofdeterminingvoltage drop on this
WIRE CHART page are for DC only. AC electricitybehaves quite
differently.
12 Vol
t

Wh at:
M etriccables are specifiedbythe copper area (in square
acceptable cable size (mm²)
millimetres),the number ofstrands ofwire and the
Cabl e Length (metres) number ofconductors or cores in each sheath. The
Amps 1 2 5 10 15 20 25 30 voltage drop is the same regardless ofvoltage,assuming
0.5 0.4 0.4 0.4 0.4 1.84 1.84 1.84 1.84 that amps,distance and cross sectional areas are the
1 0.4 0.4 0.4 1.84 1.84 1.84 1.84 1.84 same. Ifthe wattage remains the same for different
1.5 1.84 1.84 1.84 1.84 1.84 1.84 2.9 2.9 voltages,the amps can be calculatedbydividingwatts
2 1.84 1.84 1.84 1.84 1.84 2.9 4.6 4.6 byvolts.
3 1.84 1.84 1.84 1.84 2.9 4.6 4.6 7.9 TheFormul
a
4 1.84 1.84 1.84 2.9 4.6 7.9 7.9 7.9 Ifyou needto calculate the voltage drop under a given
5 1.84 1.84 1.84 4.6 4.6 7.9 7.9 13.6 set ofcircumstances,there is a formula bywhich it can
7.5 1.84 1.84 2.9 4.6 7.9 13.6 13.6 25.7 be determined.
10 1.84 1.84 4.6 7.9 13.6 13.6 13.6 25.7 Let: A = cross sectional area ofcable in (mm²)
15 1.84 1.84 4.6 13.6 25.7 25.7 25.7 32.2 L = route length in metres
20 2.9 2.9 7.9 13.6 25.7 25.7 32.2 49.2 I= current measuredin amps
25 4.6 4.6 7.9 25.7 25.7 32.2 49.2 49.2 R = resistance ofcable ( )
30 4.6 4.6 13.6 25.7 32.2 49.2 49.2 resistance ofcopper = 0.017 aluminium = 0.028
40 7.9 7.9 13.6 25.7 49.2 49.2 steel = 0.18
60 13.6 13.6 25.7 49.2 Voltage Drop = 2x L x Ix R ÷A
80 25.7 25.7 25.7 49.2
100 32.2 32.2 32.2
Example:
You have a power point connectedto a power source.
125 49.2 49.2 49.2 The route length is 8 metres. Ifthe wire is 4.6 mm²
24 Vol
t multi-strandedcopper cable andthe expectedcurrent is
expectedto be 10amps,we have:
acceptable cable size (mm²)
Cable Length (metres) A =5 L =9 I= 10 R = 0.017
Amps 1 2 5 10 15 20 25 30 Voltage drop can then be calculatedto be 0.58volts. If
1 0.4 0.4 0.4 1.84 1.84 1.84 1.84 1.84 this figure is consideredto be acceptable it wouldavoid
2 1.84 1.84 1.84 1.84 1.84 1.84 1.84 1.84 spendingmore moneyon larger wire.
3 1.84 1.84 1.84 1.84 1.84 1.84 2.9 2.9 mm² per metre 30 m rol
l ampaci
ty
4 1.84 1.84 1.84 1.84 1.84 2.9 4.6 4.6
5 1.84 1.84 1.84 1.84 2.9 4.6 4.6 4.6 1.84 twi
n sheathed W IR-M02 W IR-302 15 amps
7.5 1.84 1.84 1.84 2.9 4.6 4.6 7.9 7.9
2.9 twi
n sheathed W IR-M03 W IR-303 20 amps
10 1.84 1.84 1.84 4.6 4.6 7.9 7.9 13.6
15 1.84 1.84 2.9 4.6 7.9 13.6 13.6 25.7 4.6 twi
n sheathed W IR-M05 W IR-305 25 amps
20 2.9 2.9 4.6 7.9 13.6 13.6 25.7 25.7
25 4.6 4.6 4.6 7.9 13.6 25.7 25.7 25.7 7.9 si
ngl
e (bl
ackor red) W IR-M08 W IR-308 45 amps
30 4.6 4.6 4.6 13.6 25.7 25.7 25.7 32.2
13.6 si
ngl
e (bl
ackor red) W IR-M14 W IR-314 70 amps
40 7.9 7.9 7.9 13.6 25.7 25.7 32.3 49.2
60 13.6 13.6 13.6 25.7 32.2 49.2 49.2 25.7 si
ngl
e (bl
ackor red) W IR-M25 W IR-325 90 amps
80 25.7 25.7 25.7 25.7 49.2 49.2
100 32.2 32.2 32.2 32.2 49.2 32. si
ngl
e (bl
ackor red) W IR-M32 W IR-332 110 amps
125 49.2 49.2 49.2 49.2
49 si
ngl
e (bl
ackor red) W IR-M49 W IR-349 150 amps
NOTE: The Cable Length in the above tables are route
length which is halfthe total conductor length. Ifthe NOTE: The above cables are ratedf
or extra low voltage
positive and negative leads are different lengths an
average must be taken.
133