ElectroHub

Cable Size Calculator

A cable has to pass two separate tests: carry the current without overheating, and still deliver the voltage at the far end. On any run longer than about thirty metres it is voltage drop that decides the size, and it is the check most quick calculators leave out.

Cable size selection

A cable has to pass two tests, not one: carry the current without overheating, and deliver the voltage at the far end. On any run longer than about thirty metres it is the second that decides the size — and it is the one most quick calculators skip.

Recommended size
Capacity after derating
Voltage drop
Drop as % of supply
Suggested breaker
RCCB sensitivity
mm²Table ADerated ADrop VDrop %
1101045.7311.02too small
1.5131330.497.35too small
2.517.517.518.294.41too small
4232311.432.76too small
629297.621.84too small
1040404.571.1pick
1654542.860.69ok
2571711.830.44ok
3589891.310.31ok
501081080.910.22ok
701361360.650.16ok
951641640.480.12ok
Current ratings here are typical published values for PVC-insulated conductors in conduit at 40 °C ambient, of the kind given in IS 732 and manufacturers' tables. The derating and voltage-drop arithmetic is exact; the table values are indicative. Check the final selection against the cable maker's own data and IS 732 before anything is installed.

The formula

I_z = I_table × k_ambient × k_grouping ; V_drop = √3 × I × ρL/A [three phase]

I_table
published rating for the cable type and installation method
k_ambient
derating for ambient temperature (1.0 at 40 °C, 0.82 at 50 °C)
k_grouping
derating for circuits bunched together (0.80 for two, 0.70 for three)
ρ
resistivity at the 70 °C the conductor actually runs at — 0.0206 Ω·mm²/m for copper
L
one-way run length in metres
A
conductor cross-section in mm²

Worked example

32 A three-phase load on 415 V, 40 m of copper in conduit at 40 °C, one circuit, 3 % drop allowed.

  1. 6 mm² is rated 29 A for three loaded conductors — below 32 A, so too small
  2. 10 mm² is rated 40 A; no derating applies at 40 °C with one circuit, so I_z = 40 A ✓
  3. Voltage drop = 1.732 × 32 × (0.0206 × 40 / 10) = 4.57 V
  4. As a percentage: 4.57 / 415 = 1.10 % ✓

10 mm² copper. Capacity 40 A, drop 1.10 % — inside the 3 % limit.

Where you'll use it

Wiring a sub-circuit, a motor feeder or a submersible pump. Ratings quoted here are typical published values for PVC-insulated conductors in conduit at 40 °C, of the kind given in IS 732; the derating and voltage-drop arithmetic is exact, but check the final choice against the cable maker's own table before installing.

The laws behind it

Parts this applies to

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