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AC Cable Sizing

Inverter-to-panel AC cable size from voltage drop and current.

Electrical

Inputs (SI units)

Results

Recommended cable
2.5 mm² Copper
Design current
14.2 A
Minimum theoretical area
1.83 mm²
Actual voltage drop
6.07 V (1.46 %)
Cable power loss
0.149 kW
I²R loss at full load
Suggested breaker
20 A
≥ 1.25 × I per IEC 60364

Save & Load Project

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Engineering Formula

  • I = P / (V × pf) (1-φ)
  • I = P / (√3 × V × pf) (3-φ)
  • ρ_T = ρ₂₀ × [1 + α (T − 20)]
  • A = (2 × ρ_T × L × I) / ΔV (1-φ)
  • A = (√3 × ρ_T × L × I) / ΔV (3-φ)

AC current is derived from power, voltage and power factor, then the minimum conductor cross-section follows from the permitted voltage drop. Resistivity is corrected to the operating conductor temperature, and the result is rounded up to the next standard cross-section.

Step-by-step Calculation

  1. 1.Design currentP/(√3·V·pf)14.2 A
  2. 2.Resistivity at Tρ₂₀[1+α(T−20)]0.02058 Ω·mm²/m
  3. 3.Allowable dropV × vd%8.3 V
  4. 4.Required area√3·ρ·L·I/ΔV1.83 mm²
  5. 5.Rounded upnext standard size2.5 mm²

Design Assumptions

  • Balanced load, negligible reactance (short runs, ≤ 120 mm²).
  • Voltage drop is the governing criterion; ampacity is checked separately.
  • Standard PVC/XLPE insulated Cu/Al cable at the stated conductor temperature.

Engineering Tips

  • IEC 60364-5-52 recommends ≤ 3% drop for final circuits, ≤ 5% total.
  • Above 120 mm² include reactance — use manufacturer mV/A/m tables.
  • Apply grouping and ambient derating factors before finalising the size.

Warnings

  • Never size AC cable on voltage drop alone — verify ampacity and short-circuit withstand.
  • Aluminium requires bi-metallic lugs and higher torque checks.

Standards & References

IEC 60364-5-52 (wiring systems)IS 732 (Code of practice)IEC 60228 (conductors)

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