User: Alwayslearningelec, Location: NJ
Asked on: Thursday, April 24, 2025 at 1:42 pm EDT
Answered on: Thursday, April 24, 2025 at 1:42 pm EDT
Question: Hello I have a calculation question.Voltage is 120v.Panel is located 500’ awayTotal length 2,800’Engineer wants them fed with (4) 20a circuits.Engineer has come back and said (4) 20A circuits is not enough to feed these and we should add additional circuits as needed.Not considering voltage drop I believe I can get 1900 watts on a circuit. I would need 5 circuits to feed these correct?Fixture wattage below. Thanks
Okay, let's break this down and figure out your circuit needs. Your initial calculation of 1900 watts per circuit looks good, but we need to verify it. Then we can calculate the number of circuits needed. Finally, we need to CIRCUMVENT voltage drop because you will definitely have problems with a 500' run at 120V.1. Calculating Maximum Wattage per 20A Circuit (without Voltage Drop)
Amps
You have a 20 amp circuit.
Voltage
Your voltage is 120 volts.
Safe Load (80% rule)
NEC (National Electrical Code) typically requires circuits to be loaded to no more than 80% of their capacity for continuous loads. This is important for safety and prevents overheating. 20 amps 0.80 = 16 amps
Maximum Watts
Watts = Volts Amps 120 volts 16 amps = 1920 watts
Your initial calculation of 1900 watts is very close and reasonable.2. Determine Total Wattage of Fixtures
You need to provide the total wattage of the fixtures. I need this number to accurately calculate the number of circuits needed. Let's call that total wattage "X".3. Calculating Number of Circuits Needed (without Voltage Drop)
Circuits Needed = Total Fixture Wattage / Watts per Circuit Circuits Needed = X / 1900 watts Round Up
Always round up to the nearest whole number of circuits. You can't have a fraction of a circuit. For example, if your calculation comes out to 4.3 circuits, you need 5 circuits.
Example
Let's pretend your fixture wattage (X) totals 8000 watts. Circuits Needed = 8000 watts / 1900 watts/circuit = 4.21 circuits You would need to round up to
5 circuits.4. The BIG Problem: VOLTAGE DROP
You cannot ignore voltage drop with a 500-foot run! Voltage drop causes: Dimmer Lights Overheating of wires and potential fire hazard Reduced lifespan of fixtures Equipment malfunctionHow to Address Voltage Drop
Here's the critical information you MUST consider to deal with Voltage Drop:1.
Wire Gauge
You will likely need significantly larger wire than you might think for a 20A circuit to handle a 500-foot run at 120V. The smaller the wire gauge number (e.g., 10 AWG vs. 14 AWG), the thicker the wire and the less voltage drop.2.
Allowable Voltage Drop
Typically, a 3% voltage drop is considered acceptable. You'll need to calculate the voltage drop for your specific wire size and load.3.
Use a Voltage Drop Calculator
There are many online voltage drop calculators. You'll need to input: Amps (16 amps per circuit for your case) Voltage (120V) Wire Length (2800' total length/4 = 700' per circuit for your case) Wire Gauge (start with something like 12 AWG and see what the voltage drop is. Adjust to 10 AWG, 8 AWG, etc. until you get a voltage drop of 3% or less.) Wire Type (Copper or Aluminum - use Copper for this application)
Example - Using a Voltage Drop Calculator
Let's say, after using a voltage drop calculator with 16A, 120V, 700', and Copper wire, you find: 12 AWG wire results in an unacceptable 10% voltage drop. 10 AWG wire results in a 6% voltage drop.
8 AWG wire results in a 2.8% voltage drop (acceptable).
This means you MUST use 8 AWG wire (or larger) for your circuits. This will significantly increase the cost of the wiring.5. Important Considerations
Consult an Electrician
This type of project should be designed and installed by a qualified electrician. They can accurately calculate voltage drop, select the correct wire size, and ensure that the installation meets all applicable codes. This is especially important because you are dealing with long distances.
Alternative Voltage (if possible)
If possible, consider using a higher voltage (e.g., 240V) and step-down transformers at the fixture locations. This will significantly reduce voltage drop and allow you to use smaller wire. However, this is a more complex solution and requires careful planning and execution.*
Local Codes
Make sure to adhere to all local electrical codes and regulations.
In Summary
1. Provide the total fixture wattage ("X").
2. I can help calculate the number of circuits needed, assuming 1900 watts per circuit.3.
MOST IMPORTANTLY: Use a voltage drop calculator to determine the correct wire gauge for your 500-foot run. You will likely need a larger wire gauge than you might initially expect.4. Consult with a qualified electrician for design and installation.Ignoring voltage drop is a recipe for problems and potential hazards. Good luck! Flag for review