BY

Eng/ Ahmed Moharm

 TABLE OF CONTENTS
Introduction......................................................................................................2

Chapter 1: Factors affecting voltage drop .......................................................4

Chapter 2: Cable sizing....................................................................................7

Chapter 3: Voltage drop calculations.............................................................11

Chapter 4: Cable installation .........................................................................15

Chapter 5: Voltage drop testing .....................................................................19

Chapter 6: Conclusion ...................................................................................23

Voltage Drop Across Cables Eng/Ahmed Moharm

Introduction to Voltage Drop

• Voltage drop across cables is a common phenomenon that occurs in all electrical
systems, including those found in buildings. Voltage drop refers to the reduction
in voltage that occurs as electrical energy flows through a conductor or cable. It is
an important consideration in the design and installation of electrical systems, as
it can affect the performance of electrical equipment and even cause damage in
some cases.

• The reason for voltage drop is that all electrical conductors, including cables, have
resistance. Resistance is a property of a material that describes how much
opposition it offers to the flow of electrical current. When electrical current flows
through a conductor, it encounters resistance, which causes a voltage drop. This
voltage drop is proportional to the amount of current flowing through the
conductor and the resistance of the conductor itself.

• There are several factors that can influence the amount of voltage drop across
cables in electrical installations. One of the most significant factors is the length
of the cable. The longer the cable, the higher the resistance and the greater the
voltage drop. The cross-sectional area of the cable also plays a role. The larger the
cross-sectional area, the lower the resistance, and therefore the lower the voltage
drop. The type of material used to make the cable, the temperature of the cable,
and the current flowing through the cable are other factors that can influence
voltage drop.

• One of the primary concerns with voltage drop is its impact on the performance of
electrical equipment. As voltage drops, the amount of electrical energy that
reaches the equipment decreases, which can lead to issues such as dimming lights,
reduced motor performance, and reduced heating in electric heaters. In some
cases, voltage drop can even cause equipment to malfunction or fail entirely.

• To minimize the impact of voltage drop on electrical systems, it is important to

carefully design and install the system with proper cable sizing and installation.
The correct cable size is critical in ensuring that the voltage drop is kept within
acceptable limits. The installation of the cable is also important, as improper

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installation can cause damage to the cable or increase its resistance, leading to
higher voltage drop.

• Testing for voltage drop is also an important part of maintaining an electrical

system. Regular testing can help identify any issues with voltage drop and allow
for corrective action to be taken before any damage occurs. The use of voltage
drop tables and calculators can also help in determining the correct cable size and
length for a given installation.

In conclusion, voltage drop across cables is a natural occurrence in electrical systems

that can affect the performance of electrical equipment and even cause damage in some cases.
Understanding the factors that influence voltage drop and taking steps to minimize its impact is
critical in maintaining the safety and reliability of electrical systems. Proper design, installation,
and testing are essential in ensuring that voltage drop remains within acceptable limits and that
electrical equipment functions correctly.

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CHAPTER 1
Factors affecting voltage drop

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Voltage drop is a common issue in electrical systems, where the voltage at the end of a
circuit is lower than the voltage at the beginning of the circuit. This drop in voltage can lead to
reduced efficiency, increased energy consumption, and even equipment failure in some cases.
Understanding the factors that affect voltage drop is essential for designing and maintaining
reliable electrical systems.
The following are the main factors that affect voltage drop in electrical systems:

• Length of the Cable

The length of the cable is a critical factor that affects voltage drop. As the length of the
cable increases, the voltage drop also increases. This is because the resistance of the
cable material causes a loss of voltage. Longer cables have more resistance, which
leads to a greater voltage drop.

• Cable Size
The size of the cable is also a crucial factor that affects voltage drop. The resistance of a
cable is directly proportional to its length and inversely proportional to its cross-sectional area.
This means that a larger cable size has less resistance and, therefore, less voltage drop. Using a
smaller cable size than necessary can result in a high voltage drop and may even lead to
equipment failure.

• Current Flow
The current flow through the cable is another factor that affects voltage drop. The higher
the current flow, the higher the voltage drop. This is because the resistance of the cable increases
as the current flow increases. Therefore, it is essential to consider the maximum current capacity
of the cable when designing an electrical system to prevent high voltage drops.

• Material of the Cable

The material of the cable is also a factor that affects voltage drop. Different materials
have different resistivities, which can affect the voltage drop. For example, copper is an excellent
conductor of electricity and has a lower resistance than aluminum. Therefore, copper cables have
less voltage drop than aluminum cables.

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• Temperature of the Cable

The temperature of the cable is also a factor that affects voltage drop. As the temperature
of the cable increases, the resistance of the cable also increases. This can lead to a higher voltage
drop. Therefore, it is essential to consider the temperature rating of the cable when designing an
electrical system.

• Frequency of the Voltage

The frequency of the voltage is also a factor that affects voltage drop. In AC circuits, the
voltage changes direction, which causes the cable's resistance to increase. This increase in
resistance results in a higher voltage drop. Therefore, it is essential to consider the frequency of
the voltage when designing an electrical system.

In conclusion, voltage drop is a critical issue that can affect the performance of
electrical systems. Understanding the factors that affect voltage drop is essential for designing
and maintaining reliable electrical systems. It is important to consider the length and size of the
cable, current flow, material of the cable, temperature of the cable, and frequency of the voltage
when designing an electrical system to prevent high voltage drops. By considering these factors,
it is possible to design an efficient and reliable electrical system that operates at optimal
performance levels.

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CHAPTER 2
Cable sizing

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Cable sizing is an essential aspect of electrical system design, and it involves

selecting the appropriate size of cable to ensure the system operates efficiently and safely.
One of the critical considerations in cable sizing is voltage drop. Voltage drop is the
amount of voltage lost along a cable due to the resistance of the cable material. Excessive
voltage drop can lead to reduced efficiency and increased energy consumption. In this
article, we will discuss cable sizing related to voltage drop and how to select the right cable
size for your electrical system.

Calculating Voltage Drop

• The first step in cable sizing related to voltage drop is calculating the voltage drop for
given cable. This calculation involves using the following formula:

Vd = (mv x L x I) / 1000

Where:
Vd = voltage drop (in volts)
L = length of cable (in meters)
mv= milli volt in (mv/A/m). we get it from cables Catalogue
I= current (in amperes)

• The voltage drop is expressed in volts, and it is usually expressed as a percentage of the
voltage at the beginning of the cable. For example, a voltage drop of 2% means that the
voltage at the end of the cable is 98% of the voltage at the beginning of the cable.

Selecting the Right Cable Size

• Once you have calculated the voltage drop for a given cable, you can select the right
cable size that will ensure the voltage drop is within an acceptable range. The acceptable
range of voltage drop depends on the specific application and the standards that apply in

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the given location. In general, a voltage drop of 3% or less is considered acceptable for
most applications.

• To select the right cable size, you can use cable sizing charts or calculators. These tools
take into account the cable length, the current flow, and the acceptable voltage drop to
determine the appropriate cable size. The cable size is typically expressed in terms of
cross-sectional area, usually in square millimeters (mm2) or American Wire Gauge
(AWG).

Factors Affecting Cable Size Selection

• Several factors can affect the selection of the right cable size to ensure an
acceptable voltage drop. The most important of these factors are:

• Current Flow
The current flow through the cable is a critical factor in selecting the right cable size. The
higher the current flow, the higher the resistance of the cable, and the higher the voltage drop.
Therefore, it is essential to select a cable size that can handle the maximum current flow while
maintaining an acceptable voltage drop.

• Cable Length
The length of the cable is another critical factor in selecting the right cable size. The
longer the cable, the higher the resistance and the higher the voltage drop. Therefore, it is
essential to select a cable size that can handle the required current flow while maintaining an
acceptable voltage drop over the given cable length.

• Material of the Cable

The material of the cable is also a factor in selecting the right cable size. Different
materials have different resistivities, which affect the resistance of the cable and, therefore, the
voltage drop. Copper is an excellent conductor of electricity and has a lower resistance than
aluminum, which means that copper cables have less voltage drop than aluminum cables.

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• Temperature of the Cable

The temperature of the cable is also a factor in selecting the right cable size. As the
temperature of the cable increases, the resistance of the cable also increases, which leads to a
higher voltage drop. Therefore, it is essential to select a cable size that can handle the required
current flow while maintaining an acceptable voltage drop at the given temperature.

Conclusion

Cable sizing related to voltage drop is a critical aspect of electrical system design. The
voltage drop calculation is essential in selecting the right cable size that can handle the required
current flow while maintaining an acceptable voltage drop. It is essential to consider

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CHAPTER 3
Voltage drop calculations.

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Calculating Voltage Drop

• Voltage drop can be calculated using Ohm's Law, which states that the voltage
drop is proportional to the current and the resistance of the conductor. The
formula for voltage drop is as follows:

Voltage Drop = Current x Resistance

• Where voltage drop is measured in volts, current is measured in amperes, and

resistance measured in ohms.

To calculate the resistance of the conductor, we use the following formula:

Resistance = (Length x Resistivity) / Cross-sectional area

• Where Length is the length of the conductor, Resistivity is the resistivity of the
conductor material, and Cross-sectional area is the area of the conductor. The
resistivity of the conductor material is a constant, and it depends on the type of
material used. The cross-sectional area of the conductor depends on the current
carrying capacity and the voltage drop requirements.

• Once we have calculated the resistance of the conductor, we can use the formula
for voltage drop to calculate the voltage drop over a given length of the
conductor.

Voltage Drop Percentage

• The voltage drop percentage is the percentage of the initial voltage that is lost due
to the resistance of the conductor. It is calculated using the following formula:

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Voltage Drop Percentage = (Voltage Drop / Initial Voltage) x 100

• Where Voltage Drop is the voltage drop over the length of the conductor, and
Initial Voltage is the initial voltage at the beginning of the conductor.

• The voltage drop percentage is a critical factor in determining the appropriate

conductor size and length. In general, the voltage drop percentage should not
exceed 3% in power distribution systems and 5% in lighting systems.

Factors Affecting Voltage Drop Calculations

Several factors can affect the voltage drop calculations, and they include:

• Conductor Size
The size of the conductor is a critical factor in voltage drop calculations. A larger
conductor has a lower resistance and, therefore, a lower voltage drop. The
conductor size depends on the current carrying capacity and the voltage drop
requirements.

• Conductor Material
The material of the conductor is also a factor in voltage drop calculations.
Different materials have different resistivities, which affect the resistance of the
conductor and, therefore, the voltage drop. Copper is an excellent conductor of
electricity and has a lower resistance than aluminum, which means that copper
conductors have less voltage drop than aluminum conductors.

• Conductor Length
The length of the conductor is another critical factor in voltage drop calculations.
The longer the conductor, the higher the resistance and the higher the voltage
drop. Therefore, it is essential to select the appropriate conductor size and length
to ensure that the voltage drop is within acceptable limits.

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• Current Load
The current load is also a factor in voltage drop calculations. The higher the
current load, the higher the resistance of the conductor and the higher the voltage
drop. Therefore, it is essential to select the appropriate conductor size and length
to handle the required current load while maintaining an acceptable voltage drop.

Conclusion

• Voltage drop calculations are essential in electrical system design, and they
ensure that the system operates efficiently and safely. The voltage drop is caused
by the resistance of the conductor, and it is calculated using the formula for
voltage drop. The voltage drop percentage is a critical factor in determining the
appropriate conductor size and length. It is essential to consider the factors that
affect voltage drop calculations, such as conductor size, material, length, and
current load, to ensure

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CHAPTER 4
Cable installation

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• Cable installation is a crucial aspect of electrical system design. It involves the

process of installing electrical cables in a building or structure to provide power
and data transmission. One important factor to consider during cable installation
is the voltage drop. Voltage drop refers to the reduction of voltage in an electrical
circuit over a distance, which can result in inefficient operation of electrical
equipment and potential safety hazards. In this article, we will discuss cable
installation related to voltage drop in detail.

Selecting the Cable Size

• The size of the cable is a critical factor in voltage drop calculations. A larger cable
size has a lower resistance and, therefore, a lower voltage drop. When selecting
the cable size, it is important to consider the current load, distance, and voltage
drop requirements. The National Electric Code (NEC) provides guidelines for
selecting the appropriate cable size based on the current load and distance.

Calculating Voltage Drop

• Once the cable size is selected, it is important to calculate the voltage drop over
the length of the cable. The voltage drop is calculated using Ohm's Law, which
states that the voltage drop is proportional to the current and the resistance of the
conductor. The formula for voltage drop is as follows:

Voltage Drop = Current x Resistance

Where voltage drop is measured in volts, current is measured in amperes, and resistance
is measured in ohms.

To calculate the resistance of the conductor, we use the following formula:

Resistance = (Length x Resistivity) / Cross-sectional area

Where Length is the length of the conductor, Resistivity is the resistivity of the conductor
material, and Cross-sectional area is the area of the conductor.

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• The resistivity of the conductor material is a constant and depends on the type of
material used. The cross-sectional area of the conductor depends on the current
carrying capacity and the voltage drop requirements.

Voltage Drop Percentage

• The voltage drop percentage is the percentage of the initial voltage that is lost due
to the resistance of the conductor. It is calculated using the following formula:

Voltage Drop Percentage = (Voltage Drop / Initial Voltage) x 100

• Where Voltage Drop is the voltage drop over the length of the conductor, and
Initial Voltage is the initial voltage at the beginning of the conductor.

• The voltage drop percentage is a critical factor in determining the appropriate

cable size and length. In general, the voltage drop percentage should not exceed
3% in power distribution systems and 5% in lighting systems.

Proper Installation Techniques

• Proper installation techniques are also essential to minimize voltage drop. Cable
routing and length should be carefully planned to minimize the distance and avoid
sharp bends or tight corners, which can increase resistance and voltage drop.

• also be properly secured and supported to prevent sagging and damage to the
cable insulation. It is important to use the appropriate cable connectors and
terminals and ensure that they are properly crimped or soldered to reduce
resistance and voltage drop.

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• In addition, it is important to consider the environmental conditions during cable

installation. High temperatures can increase the resistance of the cable, resulting
in higher voltage drop. Therefore, cables installed in high-temperature
environments should have a larger cross-sectional area to compensate for the
increased resistance.

Conclusion

• In summary, cable installation related to voltage drop is a critical aspect of

electrical system design. Proper selection of the cable size, calculation of voltage
drop, and careful planning of cable routing and length are essential to minimize
voltage drop and ensure efficient operation of electrical equipment. Proper
installation techniques, including the use of appropriate connectors and terminals,
and consideration of environmental conditions, are also crucial to reduce
resistance and voltage drop. By following these guidelines, electrical engineers
can ensure that electrical systems are designed and installed to meet voltage drop
requirements and provide reliable and safe operation.

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CHAPTER 5
Voltage drop testing.

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• Voltage drop testing is a common electrical test used to evaluate the integrity of
an electrical circuit. It measures the voltage drop across a component or
connection in the circuit to determine if it is operating correctly. Voltage drop
testing is a valuable tool for diagnosing electrical problems and ensuring the safe
and efficient operation of electrical equipment. In this article, we will discuss
voltage drop testing in detail.

What is Voltage Drop Testing?

• Voltage drop testing involves measuring the voltage drop across a component or
connection in an electrical circuit. The test is performed by applying a load to the
circuit and measuring the voltage drop across the component or connection using
a voltmeter. The voltage drop is calculated by subtracting the voltage at the load
from the voltage at the source. The measured voltage drop is then compared to the
manufacturer's specifications or industry standards to determine if the component
or connection is operating correctly.

Why is Voltage Drop Testing Important?

• Voltage drop testing is important for several reasons. First, it can help identify
faulty or damaged components or connections in an electrical circuit. Excessive
voltage drop can indicate a poor connection, corroded terminals, or damaged
conductors. These issues can lead to overheating, power loss, and potential safety
hazards.

• Second, voltage drop testing can help ensure that electrical equipment is operating
efficiently. Excessive voltage drop can cause electrical equipment to draw more
current than necessary, which can lead to increased energy consumption, higher
operating costs, and reduced equipment life.

• Finally, voltage drop testing is a crucial part of electrical maintenance and

troubleshooting. It can help identify issues before they become major problems
and prevent costly downtime.

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Types of Voltage Drop Testing

There are two types of voltage drop testing: static and dynamic.

• Static voltage drop testing is performed on a circuit that is not in operation. It

measures the voltage drop across a component or connection under normal
conditions to determine if it meets manufacturer's specifications or industry
standards. Static voltage drop testing is typically performed during installation or
maintenance to ensure that the circuit is operating correctly.

• Dynamic voltage drop testing is performed on a circuit that is in operation. It

measures the voltage drop across a component or connection under load
conditions to determine if it is operating correctly. Dynamic voltage drop testing
is typically performed during troubleshooting to identify faulty or damaged
components or connections.

How to Perform Voltage Drop Testing

1. To perform voltage drop testing, follow these steps:

2. Turn off the power to the circuit and verify that it is de-energized.

3. Identify the component or connection to be tested and the test points.

4. Connect the voltmeter to the test points and set it to the appropriate voltage range.

5. Apply a load to the circuit and record the voltage drop.

6. Compare the measured voltage drop to the manufacturer's specifications or

industry standards.

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If the voltage drop is excessive, identify the cause and take corrective action.

Conclusion

• In conclusion, voltage drop testing is a valuable tool for diagnosing electrical

problems and ensuring the safe and efficient operation of electrical equipment. It
can help identify faulty or damaged components or connections, ensure efficient
equipment operation, and prevent costly downtime. By following industry
standards and best practices for voltage drop testing, electrical engineers can
ensure that electrical systems are operating correctly and safely.

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Conclusion

• In conclusion, voltage drop is a critical factor to consider in electrical system

design and installation. Excessive voltage drop can lead to equipment damage,
reduced efficiency, increased energy consumption, and potential safety hazards.
Therefore, proper calculation and management of voltage drop are essential for
ensuring the safe and efficient operation of electrical equipment.

• To minimize voltage drop, electrical engineers must carefully select the

appropriate cable size, taking into account factors such as length, load, and
environmental conditions. They must also consider the installation method and
ensure that cables are properly supported and secured. Proper installation
techniques, such as using appropriate connectors and terminals and crimping or
soldering them properly, can also reduce resistance and voltage drop.

• Voltage drop testing is a valuable tool for diagnosing electrical problems and
ensuring the safe and efficient operation of electrical equipment. It can help
identify faulty or damaged components or connections, ensure efficient equipment
operation, and prevent costly downtime.

• In summary, proper voltage drop management is crucial for the safe and efficient
operation of electrical equipment. By following industry standards and best
practices, electrical engineers can design and install electrical systems that meet
voltage drop requirements and provide reliable and safe operation.

By Eng / Ahmed Moharm

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