Answer Posted / shirish

Theory for Cable Sizing.
From Ohms law, the voltage drop in an electrical conductor is
V = I R
where
I = Current, amps
R = Resistance, Ohms

The electrical resistance can be derived from the properties of the conductor material.
R = ρ L / A
where
ρ = Resistivity, Ω mm2 /m
L = Length, m
A = Cross sectional area, mm2
Watch the units in the above equation.

The resistance can also be expressed in terms of the material conductivity (ψ) which is just the reciprocal of the resistivity.
R = L / (ψ A)

Table 1. Typical material electrical conductivity
Material Conductivity, ψ
Copper 58
Aluminium 36
Mild Steel 7.7

Combining Ohms law with the resistance expression, we get.
V = (I L) / (ψ A)

Now, we can define an acceptable voltage drop in a conductor. I have calculated the voltage drop that was used in several published tables and get around 5.5 Volts.
We could therefore re-arrange this equation to give the cable size. But cables come in standard sizes measured in mm2. In addition, you also need to consider the maximum current for each cable size.

Table 2. Conductor sizes and maximum currents
Cable Size, mm2 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300
Maximum current, A 13 21 28 36 46 61 81 99 125 160 195 220 250 285 340 395
So, the theory is relatively simple, let us now see how to use the program.

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