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An extension cord has an electrical resistance which reduces the voltage of the supply to the motor. If the cord is too long or too thin, the voltage drop will be excessive and the motor may be damaged through excessive current flow.

To keep the voltage-drop down, the right gauge of wire must be used in an extension, longer cords require thicker wire.

The usual maximum voltage drop allowed is 5% of the voltage, which on a 240 v supply is 12 v. Divide this by the current in amps and this gives the allowed resistance in the wire.

Find the resistance allowed per foot or metre, using the total length of wire, which is double the length of the cord, then use wire tables to find the wire thickness or gauge required for the cord.

Example: for a 15 amp circuit 300 feet long on 120 volts, the voltage drop allowed is 6 volts therefore the resistance must be 6/15 ohms or less (0.4 ohms). The wire length is 600 ft therefore the wire must have resistance of 0.0006 ohms per ft or less, or 0.66 ohms per 1000 ft, and wire tables show that the required gauge is #8.

But on a 240 v 15 amp system the allowed voltage drop and resistance would be doubled, so #11 wire could be used, and double the power would be available as well.

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