What Is the Voltage Drop for 4/0 AWG at 60A and 500 Feet?

4/0 AWG at 60A and 500 feet: 3.65V drop (3.04% on 120V), computed on the single-phase / DC basis. Every conductor has resistance, and longer runs at higher currents drop more voltage. Use this calculation to check whether your run clears the 3% branch-circuit drop target before pulling wire.

4/0 AWG, 60A, 500ft · single-phase / DC

3.65 V drop (3.04% on 120V)

On 120V circuit3.04%

On 240V circuit1.52%

Circuit basis: This uses the single-phase / DC round-trip formula (factor of 2) for the voltage drop across the two circuit conductors. For a three-phase line-to-line run use the three-phase version of the page (append ?type=3ph). Switch to the three-phase version →

Gauge

4/0 AWG

Amps

Feet

Drop @ 120V

3.65V (3.04%)

Assumes a 120V source on a single-phase / DC circuit. Use the circuit-basis link above to switch between single-phase/DC and three-phase.

Voltage Drop Formula (single-phase / DC)

V_drop = (2 × L × I × R) ÷ 1000

(2 × 500 × 60 × 0.0608) ÷ 1000 = 3.65 V

DC and single-phase AC use the round-trip factor of 2. Current travels out to the load on one conductor and returns on another.

For a three-phase circuit at the same amps and distance, see the three-phase version (uses √3 instead of 2, so the drop is about 13.4% lower).

Percentage

%VD = (V_drop ÷ V_source) × 100

On 120V: (3.65 ÷ 120) × 100 = 3.04%

On 240V: (3.65 ÷ 240) × 100 = 1.52%

How This Estimate Changes with Run Length and Gauge

Gauge That Meets the 3% Target

The smallest gauge in our table that clears the 3% drop target at 60A over 500ft on 120V is 250 kcmil. Shorter runs, higher source voltage, or a higher drop tolerance (feeder-only applications often accept up to 5%) can change the pick. Run the full wire-size calculator with your actual variables.

Impact of Distance

Voltage drop is proportional to distance. Here is 4/0 AWG at 60A at different distances:

Distance	Drop (V)	% on 120V	% on 240V	NEC (120V)
25ft	0.1824V	0.152%	0.076%	OK
50ft	0.3648V	0.304%	0.152%	OK
75ft	0.5472V	0.456%	0.228%	OK
100ft	0.7296V	0.608%	0.304%	OK
150ft	1.09V	0.912%	0.456%	OK
200ft	1.46V	1.22%	0.608%	OK
300ft	2.19V	1.82%	0.912%	OK

Same Run, Different Wire Gauges

How does wire gauge affect voltage drop for 60A at 500 feet on 120V single-phase / DC? Only gauges whose branch-circuit OCP cap is at or above the 60A load are listed, since thinner gauges would fail the ampacity check before drop even matters.

Gauge	Drop (V)	% on 120V	% on 240V	3% Target (120V)
4/0 AWG	3.65V	3.04%	1.52%	Caution
250 kcmil	3.09V	2.57%	1.29%	OK
300 kcmil	2.57V	2.15%	1.07%	OK
350 kcmil	2.2V	1.83%	0.9175%	OK
500 kcmil	1.55V	1.29%	0.645%	OK
750 kcmil	1.03V	0.855%	0.4275%	OK

Related Calculations

cable Wire size: 60A, 500ft bolt Watts to amps calculator functions Voltage drop formula

Frequently Asked Questions

What is the voltage drop for 4/0 AWG at 60A and 500ft?expand_more

4/0 AWG carrying 60A over 500ft has a 3.65V drop (3.04% on 120V). Reference: 1.52% on 240V.

What happens if voltage drop is too high?expand_more

Motors run hotter and can have trouble starting under load. Incandescent and halogen lighting dims. Some electronics misbehave at the low end of their input tolerance. Energy is wasted as I²R heating in the conductor. These are performance issues; high drop is not itself a code violation unless the specific installation cites a hard limit.

What wire gauge should I use instead of 4/0 AWG for this run?expand_more

This run is at 3.04% on 120V, past the 3% branch-circuit drop target. If you want to land under 3% at 60A over 500ft on 120V, the smallest gauge in our table that clears it is 250 kcmil at 2.57%. Going up one size from 4/0 AWG is not always enough, each AWG step only drops the resistance by roughly 20-25%, so on long runs or high currents you often have to skip one or two sizes to meet the target. NEC 210.19(A) Informational Note 4 frames 3% as a recommendation, not a code requirement, so the right answer for you also depends on the load (motor startup, sensitive electronics) and how much drop is tolerable.

How do I reduce voltage drop?expand_more

Use a larger wire gauge (lower AWG number), shorten the run, or increase the source voltage. Each option reduces the percentage drop, and higher source voltage is usually the most effective change for long runs because the drop is a smaller fraction of a larger reference.

Why does distance affect voltage drop?expand_more

Voltage drop is proportional to distance. The formula multiplies by 2 × the distance (out and back). Doubling the run doubles the drop.

This calculator provides estimates for reference purposes only. Always consult a licensed electrician and verify compliance with the National Electrical Code (NEC) and local electrical codes before performing any electrical work.