Wire Sizing Engineerdog

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Disclaimer: Calculations are for approximate use only. I assume no liability for the u
*AC or DC doesn’t matter (up to ~2000 volts).
*Wire ampacity decreases if: room temperature increases, multiple conductors are b
*Calculations are intended for standard electrical wire. "Welding wire" is treated a b
*Stranded wire has the same ampacity as solid wire for all practical intents and purp
*Ampacity based on data from 2008 NEC, Table 310.16.

Input Wire D
(these dime

System Voltage (AC


Wire Material or DC doesn’t matter up to AWG Size/gage
2000 volts)

(copper or aluminum) (Volts) (4/0) - 50

copper 120 18

Wire Charac
Wire Diameter Wire Cross-Section Area
(in) (in^2) (circular mils)

0.040 8.25 1,624

Calculated Voltage Dro


(Usually this is more important for smaller ga

Expected Maximum
Current Voltage Drop/Loss

(amp) (volts) (%)


10.61 0.69 0.57

CABLE SIZES - NOT DRAWN TO SCALE


ress Tab to Cycle Through Input Variables

me no liability for the use or misuse of this calculator.

ultiple conductors are bundled, or if conductors are inserted into conduit.


ing wire" is treated a bit differently as seen in the table at the bottom.
ctical intents and purposes.

Input Wire Dimensions Below in Red


(these dimensions apply to all calculations)

Total Length of Wire


Used Ambient Temperature

(ft) (°F) (°C)

10 72.0 22.22

Wire Characteristics
Wire Weight Resistance Rated Ampacity
(lb) (W) (amp)

0.05 0.065 10.61

ated Voltage Drop


ore important for smaller gage wires)

Power Loss
(heat generated) Distance before 3% voltage drop

(w) (ft)
7.27 53
Number of Bundled Rated Wire
Wires in Sheath Temperature
(60 °C is normal)

# (60, 75, 90 °C)

3 60

Rated Wattage
(Watts)

1273
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AWG and B&S Diameter and Cross-Section


Areas

Ref # 22

Diameter Cross Section Area


AWG or
B&S Square
Number Inches mm Inches

(4/0) 0.46 11.68 0.1662

(3/0) 0.4096 10.4 0.1318


(2/0) 0.3648 9.266 0.1045

(1/0) 0.3249 8.252 0.08289

1 0.2893 7.348 0.06573

2 0.2576 6.543 0.05123

3 0.2294 5.827 0.04134

4 0.2043 5.189 0.03278

5 0.1879 4.62 0.026


6 0.162 4.115 0.02062

7 0.1443 3.665 0.01635

8 0.1285 3.264 0.01297

9 0.1144 2.906 0.01028

10 0.1019 2.588 0.008156

11 0.09074 2.305 0.006467

12 0.08081 2.053 0.005129

13 0.07196 1.828 0.004067

14 0.06408 1.628 0.003225

15 0.05707 1.45 0.002558

16 0.05082 1.291 0.002028


17 0.04526 1.15 0.001609
18 0.0403 1.024 0.001276
19 0.03589 0.9116 0.001012

20 0.03196 0.8118 0.000802

21 0.02846 0.7229 0.000636

22 0.02535 0.6439 0.000505

23 0.02257 0.5733 0.0004

24 0.0201 0.5105 0.000317


25 0.0179 0.4547 0.000252
26 0.01584 0.4049 0.0002
27 0.0142 0.3607 0.000158
28 0.01264 0.3211 0.000126
29 0.01126 0.286 9.95E-05
30 0.01003 0.2548 7.89E-05
31 0.008928 0.2268 6.26E-05
32 0.00795 0.2019 4.96E-05
33 0.00708 0.1796 3.94E-05
34 0.006305 0.1601 3.12E-05
35 0.005615 0.1426 2.48E-05
36 0.005 0.127 1.96E-05
37 0.004453 0.1131 1.56E-05
38 0.003965 0.1007 1.24E-05
39 0.003531 0.0897 9.79E-06
40 0.003145 0.0799 7.77E-06
41 0.0028 0.0711 6.16E-06
42 0.002494 0.0633 4.88E-06
43 0.002221 0.0564 3.87E-06
44 0.001978 0.0502 3.07E-06
45 0.001761 0.0447 2.44E-06
46 0.001568 0.0398 1.93E-06
47 0.001397 0.0355 1.53E-06
48 0.001244 0.0316 1.22E-06
49 0.001107 0.0281 9.6E-07
50 0.000986 0.0251 7.6E-07
eter and Cross-Sectional
reas

Cross Section Area K


est 60 C (constant Wire Wire
Square Circular ampacity value for Area Area
ohms/mi (circular
mm Mils (ft) copper)
l-foot (in^2) mils)
short Length (do
not change!) 55.1 10.4 0.0013 1624
107.2 211600 195 1

(ft) ohms/mi (in^2) (circular


85.03 167800 165 2 Long length (do l-foot mils)
not change!)
Long length (do
not change!)
243 10.4 0.0013 1624
67.43 133100 145 3
ohms/mi (circular
short & shroud (ft) (in^2)
53.48 105500 125 4 l-foot mils)
length (do not
change!) 98 10.4 0.0013 1624
42.41 83690 110 5

33.63 66370 95 6

y = 0.000000x5 - 0.000000x4 + 0.000000x3 - 0.000000x2 + 0.001951x + 13.050349


26.27 52630 82.5 7
R² = 0.999764
21.15 41740 70 8

16.77 33100 62.5 9


13.3 26250 55 10 COPPER ALUMINUM
Allowable Allowable
Conduc
tor
10.55 20820 47.5 11
Size Ampacities* Ampacities*
8.366 16510 40 12
AWG
or 60°C 75°C 90°C 60°C 75°C
6.634 13090 35 13 kcmil
TYPES
THWN-2,
TYPES USE-2, TYPES
THWN, XHHW-2, THWN,
RHW, USE XHHW, RHW, USE
RHW-2,
RHH
5.261 10380 31 14

4.172 8234 27 15 8 40 50 55 30 40

3.309 6530 23 16 6 55 65 75 40 50

2.624 5178 20 17 4 70 85 95 55 65

2.081 4107 17 18 2 95 115 130 75 90

1.65 3257 15 19 1 110 130 150 85 100

1.309 2583 13 20 (1/0) 125 150 170 100 120


1.038 2048 11 21 (2/0) 145 175 195 115 135
0.8231 1600 10 22 (3/0) 165 200 225 130 155
0.6527 1288 9 23 (4/0) 195 230 260 150 180

0.5176 1022 7 24

0.4105 810.1 6 25

0.3256 642.4 6 26

0.2582 509.5

0.2047 404
0.1624 320.4 Factor
0.1288 254.1 CU AL
0.1021 201.5 60 75 90 60 75
0.08098 159.8 1 1.204 1.359 1 1.212
0.06422 126.7
0.05093 100.5 1.08 1.26 1.41 1.08 1.27
0.04039 79.7 Ambient 1.08 1.05 1.04 1.08 1.05
0.03023 63.21 6 1.32 1.2 1.16 1.32 1.2
0.02545 50.22 7 1.32 1.2 1.16 1.32 1.2
0.02014 39.75 8 1.32 1.2 1.16 1.32 1.2
0.01597 31.52 9 1.32 1.2 1.16 1.32 1.2
0.01267 25 10 1.32 1.2 1.16 1.32 1.2
0.01005 19.83 11 1.32 1.2 1.16 1.32 1.2
0.00797 15.72 12 1.24 1.15 1.12 1.24 1.15
0.00632 12.47 13 1.24 1.15 1.12 1.24 1.15
0.00501 9.888 14 1.24 1.15 1.12 1.24 1.15
0.00397 7.842 15 1.24 1.15 1.12 1.24 1.15
0.00315 6.219 16 1.16 1.1 1.08 1.16 1.1
0.0025 4.932 17 1.16 1.1 1.08 1.16 1.1
0.00198 3.911 18 1.16 1.1 1.08 1.16 1.1
0.00157 3.102 19 1.16 1.1 1.08 1.16 1.1
0.00125 2.46 20 1.16 1.1 1.08 1.16 1.1
0.00099 1.951 21 1.08 1.05 1.04 1.08 1.05
0.00078 1.547 22 1.08 1.05 1.04 1.08 1.05
0.00062 1.227 23 1.08 1.05 1.04 1.08 1.05
0.00049 0.973 24 1.08 1.05 1.04 1.08 1.05
25 1.08 1.05 1.04 1.08 1.05
26 1 1 1 1 1
27 1 1 1 1 1
28 1 1 1 1 1
29 1 1 1 1 1
30 1 1 1 1 1
31 0.91 0.94 0.96 0.91 0.94
32 0.91 0.94 0.96 0.91 0.94
33 0.91 0.94 0.96 0.91 0.94
34 0.91 0.94 0.96 0.91 0.94
35 0.91 0.94 0.96 0.91 0.94
36 0.82 0.88 0.91 0.82 0.88
37 0.82 0.88 0.91 0.82 0.88
38 0.82 0.88 0.91 0.82 0.88
39 0.82 0.88 0.91 0.82 0.88
40 0.82 0.88 0.91 0.82 0.88
41 0.71 0.82 0.87 0.71 0.82
42 0.71 0.82 0.87 0.71 0.82
43 0.71 0.82 0.87 0.71 0.82
44 0.71 0.82 0.87 0.71 0.82
45 0.71 0.82 0.87 0.71 0.82
46 0.58 0.75 0.82 0.58 0.75
47 0.58 0.75 0.82 0.58 0.75
48 0.58 0.75 0.82 0.58 0.75
49 0.58 0.75 0.82 0.58 0.75
50 0.58 0.75 0.82 0.58 0.75
51 0.41 0.67 0.76 0.41 0.67
52 0.41 0.67 0.76 0.41 0.67
53 0.41 0.67 0.76 0.41 0.67
54 0.41 0.67 0.76 0.41 0.67
55 0.41 0.67 0.76 0.41 0.67
56 0 0.58 0.71 0 0.58
57 0 0.58 0.71 0 0.58
58 0 0.58 0.71 0 0.58
59 0 0.58 0.71 0 0.58
60 0 0.58 0.71 0 0.58
61 0 0.33 0.58 0 0.33
62 0 0.33 0.58 0 0.33
63 0 0.33 0.58 0 0.33
64 0 0.33 0.58 0 0.33
65 0 0.33 0.58 0 0.33
66 0 0.33 0.58 0 0.33
67 0 0.33 0.58 0 0.33
68 0 0.33 0.58 0 0.33
69 0 0.33 0.58 0 0.33
70 0 0.33 0.58 0 0.33
71 0 0 0.41 0 0
72 0 0 0.41 0 0
73 0 0 0.41 0 0
74 0 0 0.41 0 0
75 0 0 0.41 0 0
76 0 0 0.41 0 0
77 0 0 0.41 0 0
78 0 0 0.41 0 0
79 0 0 0.41 0 0
80 0 0 0.41 0 0
extrapolated
250
copper
aluminu
200
m

150
Ampacity

100

50 Multiple Conductor
Correction Factors

0
0 50000 100000 150000 200000 Number of
wire area Conductors

4-6
Resistan
7-9
ce wire
(ohms) ft in volume 10-20

0.3528 10.0000 120.0000 0.1531 in^3 21-30


6.40359

(ohms) 31-40
1.5561 41+
6.40359
copper 0.3240
(ohms) density
lb/in^3
Aluminu
0.6276 m 0.0980 lb/in^3
6.40359 Density

known
250
200
f(x) = 0.110000304521133 x^0.608891505190569
Ampacity
150 R² = 0.999373592628404
100
50

ALUMINUM 0
0 50000 100000 150000 200000 250000
Allowable
Conduc
number oder
tor

mpacities* Size MATERIAL FACTOR


AWG
90°C or
kcmil 1.204 1.359 1.212 1.380 0.780124260358383
TYPES
THWN-2,
USE-2,
XHHW-2,
XHHW,
RHW-2,
RHH
CONDUCTOR RATED TEMPERATURE FACTOR
45 8 1.250 1.375 1.333 1.500 0.75
60 6 1.182 1.364 1.250 1.500 0.72727273
75 4 1.214 1.357 1.182 1.364 0.78571429
100 2 1.211 1.368 1.200 1.333 0.78947368
115 1 1.182 1.364 1.176 1.353 0.77272727
135 Jan-00 1.200 1.360 1.200 1.350 0.8
150 Feb-00 1.207 1.345 1.174 1.304 0.79310345
175 Mar-00 1.212 1.364 1.192 1.346 0.78787879
205 Apr-00 1.179 1.333 1.200 1.367 0.76923077

http://www.safecoelectric.com/images/resources_pdf/NEC2008%20Table%20310.16.pdf
AL
90 cu al
1.380 60 1.08 0.84
75 1.26 0.99
1.43 matched & multplied b 4 90 1.41 1.12
1.04 matched 3
1.16 22.0 rounded 1 SUM table 5
1.16 17 indexed 2 1.08 0
1.16 0 0
1.16 0 0
1.16
1.16 1.08 6
1.12 final factor (accoutns for material, temp rating,
1.12 and ambent temp)
1.12
1.12
1.08
1.08
1.08
1.08
1.08
1.04
1.04
1.04
1.04
1.04
1
1
1
1
1
0.96
0.96
0.96
0.96
0.96
0.91
0.91
0.91
0.91
0.91
0.87
0.87
0.87
0.87
0.87
0.82
0.82
0.82
0.82
0.82
0.76
0.76
0.76
0.76
0.76
0.71
0.71
0.71
0.71
0.71
0.58
0.58
0.58
0.58
0.58
0.58
0.58
0.58
0.58
0.58
0.41
0.41
0.41
0.41
0.41
0.41
0.41
0.41
0.41
0.41
tiple Conductor
rection Factors
1 1 match the right factor
Multiply
ampacity
by factor 2 1 3 1
0.8
3 1 accounts for bundles of wire
0.7 4 0.8
0.5 5 0.8

0.45
6 0.8

0.4
7 0.7
0.35
8 0.7

9 0.7

10 0.5

11 0.5

12 0.5

13 0.5

14 0.5
15 0.5
200000 250000

16 0.5

MATERIAL FACTOR 17 0.5

0.780124260358383 18 0.5

19 0.5

0.8 0.81818 20 0.45

0.76923 0.8 21 0.45

0.76471 0.78947 22 0.45

0.78261 0.76923 23 0.45

0.76923 0.76667 24 0.45

0.8 0.79412 25 0.45


0.77143 0.76923 26 0.45
0.775 0.77778 27 0.45
0.78261 0.78846 28 0.45

29 0.45

30 0.45

31 0.4

32 0.4

33 0.4
34 0.4
35 0.4
36 0.4
37 0.4
38 0.4
39 0.4
40 0.4
41 0.35
42 0.35
43 0.35
44 0.35
45 0.35
46 0.35
aterial, temp rating, 47 0.35
emp) 48 0.35
49 0.35
50 0.35

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