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Measuring voltage drop under load

Measure the real voltage drop — not just the calculated one

Voltage drop must not only be calculated but measured under expected load as part of testing. Too great a drop gives dim lighting, poorly running motors and unnecessary energy loss in the cable.

  1. Know the limits before you measure

    Annex G (table G.52.1) recommends max. 3 % voltage drop for lighting and max. 5 % for other installations when the installation is supplied directly from the public low-voltage network (type A). With a private supply, e.g. its own transformer (type B), the figures are 6 % and 8 %. The annex is informative, not a legal requirement. Lighting is more sensitive and therefore has the stricter limit.

    Lightingmax. 3 %Othermax. 5 %
  2. Put the system under expected load

    Load the circuit with the load it is designed for. The voltage drop increases with the current, so a measurement without load says nothing about the operating situation.

  3. Measure the voltage at the board and at the load

    Measure the voltage at the start of the circuit (the board) and at its end (the load) simultaneously, or use the instrument's built-in voltage drop function (Z measurement), which calculates the drop from the loop impedance.

  4. Calculate the fall as a percentage

    Convert the voltage drop into a percentage of the nominal voltage (230 V phase / 400 V line). Compare with the formula ΔU = (k · L · I · cos φ) / (κ · A) from the voltage drop calculator to reveal unexpected deviations.

    κ copper≈ 44.4 m/(Ω·mm²)κ aluminium≈ 27.8 m/(Ω·mm²)
  5. Assess the result against the limit

    If the 3 %/5 % limit is exceeded, the cable is too long or too thin for the load. The solution is a larger cross-section, a shorter run or relieving the circuit — not ignoring the drop.

  6. Remember that voltage drop is only one of three requirements

    Even if the voltage drop is acceptable, current-carrying capacity (installation method) and short circuit must always be checked separately according to the DS/HD 60364-5-52 tables. The largest of the three requirements determines the cross-section.

    Record the measured load together with the voltage drop — a drop without a stated load cannot be verified.

Source

Based on DS/HD 60364-5-52, Annex G (recommended voltage drop limits, table G.52.1) and the trade's article »Voltage drop«.

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