How Wire Size Is Determined
Selecting the correct wire size involves satisfying two independent criteria — the larger wire required by either criterion must be used:
- Ampacity: The wire must carry the load current without overheating. Set by NEC 310.15 tables based on conductor type, insulation rating and installation method.
- Voltage drop: The wire must be large enough to keep voltage drop within acceptable limits (typically ≤3% for branch circuits).
Long runs almost always require a larger wire for voltage drop reasons even when the ampacity requirement is met by a smaller gauge.
Frequently Asked Questions
What wire size do I need for a 20-amp circuit?
#12 AWG copper wire is required for a 20-amp branch circuit. #14 AWG is only rated for 15-amp circuits and cannot be used on a 20-amp breaker.
What size wire for a 100-amp sub-panel 150 feet away?
For a 100-amp feeder at 150 ft with 240V single-phase, #1 AWG copper or #2/0 AWG aluminum is typically required to keep voltage drop under 3%. Always verify with a licensed electrician.
Does conduit fill affect wire ampacity?
Yes. When more than 3 current-carrying conductors share a conduit, ampacity must be derated per NEC 310.15(C). This calculator does not apply conduit fill derating — consult an electrician for multi-conductor installations.