How to read the voltage drop chart
Pick the row for the copper wire size and the column for the load in amps. The number is the longest one-way run, in feet, that keeps the voltage drop at or below 3% on a single-phase, two-wire circuit. If your run is longer, move down to a larger wire until the distance in that column covers it.
A dash means the wire is too small for that current in the first place: the load exceeds the 75°C ampacity in NEC Table 310.16 or the 240.4(D) breaker limit. Ampacity always comes first; voltage drop only ever pushes the size up. The wire ampacity chart has the full table.
The formula behind it
VD = 2 × K × I × L ÷ CM
VD is the voltage drop in volts, K is the resistivity constant (12.9 ohm-cmil/ft for copper, 21.2 for aluminum, both at 75°C), I is the current in amps, L is the one-way length in feet and CM is the conductor area in circular mils from NEC Chapter 9 Table 8. Rearranged for distance, L = VD × CM ÷ (2 × K × I), which is what generates every cell above.
Worked example: a 16 A load on 12 AWG copper 60 feet from the panel at 120 V gives 2 × 12.9 × 16 × 60 ÷ 6,530 = 3.79 V, or 3.2%. That is just over the 3% target. Moving up to 10 AWG (10,380 cmil) gives 2.39 V, or 2.0%.
Why 240 volts goes twice as far
The drop in volts for a given wire and current is the same at 120 V and 240 V. But 3% of 240 V is twice as many volts as 3% of 120 V, so the allowable distance doubles. That is one reason well pumps, heat pumps and other long-run loads are usually 240 V.
Common voltage drop mistakes
- Entering the round-trip length; the formula already accounts for both conductors.
- Using the copper K for aluminum conductors.
- Ignoring motor starting current, which can briefly cause several times the running drop.
- Treating the chart as an ampacity table. Check Table 310.16 first.
The K-factor method uses DC resistance. For large conductors on AC circuits, especially in steel conduit, NEC Chapter 9 Table 9 impedance gives a slightly more exact result. Conductor data is from NFPA 70, 2023 edition; local amendments may apply.