Engineering workspace · preliminary

Plan your DC circuits.

Estimate copper conductor voltage drop, build a two-conductor cut list, and track protection and installation checks. All calculations are indicative until reviewed for the actual installation.

1. Circuit details

Enter a single DC load circuit. Length is the one-way routed distance from supply to load.

Circuit name

Nominal voltage

Design current (A)

One-way cable route (m)

Copper conductor (mm²)

Purchase waste allowance (%)

Voltage-drop target (%)

Termination / routing extra per end (m)

Cable price per metre (AUD, optional)

2. Simplified wiring path

DC source / busbar

DC fuse / protection
TBD

DC load

Conceptual positive conductor path only. The negative return must also be sized and routed; system-level shunt, earthing, isolators and fault protection are not shown.

3. Cut list and purchasing

Each circuit includes one positive and one negative conductor. Allowance per end applies to each conductor; waste is applied after cut lengths. Aggregated totals are rounded up to 0.5 m purchase increments by conductor size and polarity.

Circuit	Conductor	Cut each	Purchase total
No circuits added

Live circuit estimates

Voltage drop——

Resistance—Positive + negative

Each cut length—Per polarity

Combined purchase—Before grouped rounding

Model: copper resistivity 0.0175 Ω·mm²/m at approximately 20°C. Total conductor length = 2 × one-way route; additional termination length is included in the cut list, not the voltage-drop route calculation. Actual operating temperature and connection/fuse/shunt resistance increase voltage drop.

4. Mandatory design verification

Cable ampacity checked for installation method, bundling and temperature Fuse rating, speed/type, voltage and conductor protection verified Fuse DC interrupt rating checked against prospective battery-bank short-circuit current Manufacturer terminals, ferrules/lugs, crimp tools and torque verified Busbars, isolators, shunt placement, return path and enclosure protection reviewed

Checking these boxes is only a planning record, not proof of compliance. Lithium battery short-circuit protection requires special attention. Do not build or energise a system from this prototype alone.

5. Materials and tools checklist

Red and black cable of selected sizes
Correctly rated fuses and holders (to be engineered)
Manufacturer-approved lugs / ferrules
Adhesive-lined heat shrink where appropriate
Insulation, loom, conduit, grommets and labels
Suitable cable cutters and insulation strippers
Correct calibrated crimping tool and dies
Torque tools and multimeter
Appropriate PPE and verification equipment

Quantities for connectors, protection, tools and heat shrink are pending circuit-specific termination specifications.

VoltPlan technical prototype v0.2 · Not an installation drawing or compliance certificate. Obtain competent engineering review and follow applicable Australian standards and manufacturer instructions.