Wire Size Calculator — Ampacity + Voltage Drop

Copper gauge from the NEC 75°C column, then checked against voltage drop.

Quick answer: Enter amps, voltage and run length to get the smallest copper gauge passing ampacity and voltage-drop limits together, with numbers shown for both checks.

📏 Continuous loads (running 3+ hours) must be sized at 125% of the load — enter the multiplied amps, not the nameplate. Copper only; aluminum needs its own math.

How to use

  1. Enter the load in amps and the circuit voltage (120, 240, 277, 480…).
  2. Enter the one-way run length in feet and a max drop — 3% is standard.
  3. Pick single-phase or three-phase.
  4. Read the ampacity pick, its voltage-drop result, and the smallest gauge passing both.

About this tool

Undersized wire runs hot and drops voltage; oversized wire just costs money — this wire size calculator finds the smallest copper conductor that passes both tests at once. Ampacity comes from the NEC 75°C column with the small-conductor caps electricians apply: 14 AWG tops out at 15 amps, 12 AWG at 20, and 10 AWG at 30. Voltage drop uses the standard VD = 2 × K × I × L ÷ CM formula with K = 12.9 for copper, evaluated against your one-way run length, circuit voltage and a configurable drop limit — 3 percent is the usual branch target. The result names the gauge that satisfies ampacity, shows whether it also passes the drop check, and if it does not, keeps stepping up until one does, printing the numbers behind both tests. Long runs, low voltage and big loads are where voltage drop quietly wins. Educational estimate — always verify against the current NEC before pulling wire.

FAQ

What size wire do I need for 20 amps?
For a typical short run, 12 AWG copper handles 20 amps under the small-conductor rule. But run that circuit 100 feet at 120 V and voltage drop pushes you to 10 or even 8 AWG — which is precisely why this calculator checks drop instead of stopping at the ampacity table.
How is voltage drop calculated?
For single-phase: VD = 2 × K × I × L ÷ CM, with K = 12.9 ohm-cmil/ft for copper, I the load current, L the one-way length in feet, and CM the conductor's circular-mil area. Divide by circuit voltage for the percentage. Three-phase swaps the 2 for √3 (about 0.866 of the single-phase result).
What is an acceptable voltage drop?
A common design target is under 3 percent for a branch circuit, or 5 percent total from service to load (NEC 210.19 informational note). Sensitive electronics and motors care more than heaters do — dimming lights and sluggish motors are the classic symptoms of ignoring it.
Does this table work for aluminum wire?
No — this tool is copper only. Aluminum conducts about 61% as well as copper (use K ≈ 21.2) and has its own ampacity columns plus special termination rules, so an aluminum circuit needs its own calculation and usually one or two sizes up.
Why does 14 AWG show 15 A when tables say 20 A?
The NEC 75°C column lists 20 A for 14 AWG, but the small-conductor rule (240.4(D)) caps overcurrent protection at 15 A for 14 AWG, 20 A for 12 and 30 A for 10 — the numbers this calculator applies. Special motor and HVAC circuits can compute differently.

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