When you hear the phrase “what size copper wire for 100 amp service,” it refers to the correct wire gauge required to safely handle a 100-amp electrical load. The wire must be thick enough to carry the current without overheating or creating resistance that can cause voltage drops. Electrical wires are rated by their American Wire Gauge (AWG) number, where smaller numbers indicate thicker wires. Selecting the proper size ensures your electrical system operates efficiently and prevents potential hazards like fires or power loss. Essentially, the right copper wire size keeps your system safe, durable, and code-compliant.
Use #4 AWG copper wire for a standard 100 amp service; for longer runs, upgrade to #3 or #2 AWG to reduce voltage drop.
In this article, we discuss the topic of “what size copper wire for 100 amp service”.
Importance of Choosing the Correct Wire Size for 100 Amp Service
Choosing the correct copper wire size for 100 amp service is crucial because it directly affects the performance and safety of your entire electrical system. A wire that’s too small can overheat, melt insulation, and even start fires. On the other hand, using a wire that’s too large can be unnecessarily expensive and difficult to work with. Proper sizing ensures that your circuit runs efficiently and your appliances receive consistent voltage. It also prevents premature equipment failure and complies with local building codes. Simply put, the right wire size saves energy, money, and lives.
What Is a 100 Amp Service Panel?
A 100 amp service panel is the central hub of an electrical system that distributes electricity throughout a building. It’s commonly found in medium-sized homes and small commercial buildings. This panel includes a main breaker rated at 100 amps, which protects the system from overloading. The panel’s capacity determines how much electrical load your home can handle simultaneously. Choosing the correct copper wire for this panel ensures that electricity flows safely from the utility meter to the panel without overheating or voltage loss. In essence, it’s the control center of your electrical infrastructure.
The Role of Copper Wire in Electrical Systems
Copper wire plays a vital role in every electrical system because of its excellent conductivity and durability. Compared to aluminum, copper can carry more current with less resistance, which means less energy loss as heat. Copper is also more flexible and resistant to corrosion, making it ideal for both indoor and outdoor installations. In a 100 amp service, copper wire ensures stable current flow, reduces fire risks, and maintains consistent voltage levels across circuits. This is why most electricians prefer copper for main panels, sub-panels, and feeder lines.
Why Copper Wire Is Preferred Over Aluminum for 100 Amp Service
Copper wire is preferred over aluminum for 100 amp service for several reasons. Firstly, copper conducts electricity more efficiently, requiring smaller wire gauges for the same current capacity. Secondly, copper expands and contracts less with temperature changes, reducing the risk of loose connections over time. Aluminum, while cheaper, is more prone to oxidation, which can lead to poor connections and fire hazards. Additionally, copper wiring is easier to install and bend, making it more user-friendly. Although copper is costlier, its long-term reliability justifies the investment for any 100 amp setup.
The National Electrical Code (NEC) Guidelines for 100 Amp Wiring
The National Electrical Code (NEC) provides standards to ensure safe electrical installations across the U.S. According to NEC guidelines, a 100 amp service typically requires a minimum of #4 AWG copper wire or #2 AWG aluminum wire for short distances. However, these recommendations can vary depending on factors like distance, voltage drop, and installation type (underground or overhead). Following NEC rules isn’t optional—it’s mandatory. Compliance ensures that your system is safe, efficient, and approved for inspection. Always check the latest NEC version before starting any electrical project.
What Gauge Wire Is Needed for 100 Amp Service?
The standard wire gauge for a 100 amp copper service is #4 AWG. However, if the distance between the power source and the panel is long, you may need to size up to #3 AWG or #2 AWG to compensate for voltage drop. The gauge number directly correlates with the wire’s thickness—the smaller the number, the thicker the wire. Thicker wires allow more current to flow safely without excessive heating. Always calculate the total distance and load requirements before finalizing your wire gauge to ensure safety and efficiency.
How Distance Affects Wire Size for 100 Amp Service
Distance plays a major role in determining the proper copper wire size for a 100 amp service. The longer the wire run, the more resistance electricity encounters, resulting in voltage drop. This drop can cause lights to dim, appliances to underperform, or even damage sensitive electronics. To counter this, electricians increase the wire thickness to maintain consistent voltage at the end of the circuit. For example, a 100 amp service located 200 feet away may require #2 AWG instead of #4 AWG. Always factor distance into your wire size calculations.
Voltage Drop Considerations for 100 Amp Circuits
Voltage drop is the decrease in voltage as electricity travels through a wire. In a 100 amp circuit, it’s essential to keep voltage drop below 3% for optimal performance. Excessive voltage drop can cause motors to overheat and lights to flicker. The amount of voltage lost depends on wire size, material, length, and load current. Copper wire, being a superior conductor, minimizes this drop compared to aluminum. Using an online voltage drop calculator can help you determine if you need to upsize your wire for long-distance runs.
What Size Copper Wire for 100 Amp Service at 100 Feet Distance
For a 100 amp service located about 100 feet away from the power source, #3 AWG copper wire is typically recommended. This accounts for minimal voltage drop while maintaining NEC compliance. While #4 AWG may technically handle 100 amps, upsizing to #3 ensures safety and better performance. Using the correct wire gauge prevents overheating and keeps your system efficient over time. Always double-check calculations based on your specific installation conditions and local code requirements.
What Size Copper Wire for 100 Amp Service at 150 Feet Distance
When your 100 amp service is 150 feet away from the main panel, you’ll need to compensate for voltage drop by using a thicker wire. In this case, #2 AWG copper wire is recommended. This size ensures that current travels efficiently without losing significant voltage across the distance. Using a smaller wire at this distance can lead to energy waste and potential overheating. Always measure your total run length and consider upsizing your wire to maintain power stability, especially if heavy-duty appliances are involved.
What Size Copper Wire for 100 Amp Service at 200 Feet Distance
For a 200-foot run, the voltage drop becomes even more significant. Therefore, a #1 AWG copper wire is recommended for a 100 amp service at this distance. This thicker wire minimizes voltage loss and keeps your system running safely and efficiently. If you use undersized wiring for such a long run, lights may flicker, and equipment may suffer from low voltage. Remember that safety and efficiency always outweigh the small additional cost of thicker wire in long-distance installations.
Differences Between THHN, THWN, and XHHW Copper Wires
THHN, THWN, and XHHW are different types of copper wire insulation, and each is suited to specific environments. THHN (Thermoplastic High Heat-Resistant Nylon-Coated) wire is great for dry locations and high temperatures. THWN (Thermoplastic Heat and Water-Resistant Nylon-Coated) wire adds water resistance, making it ideal for damp areas. XHHW (Cross-Linked High Heat-Resistant Water-Resistant) offers even better insulation for outdoor or underground use. For 100 amp service, your choice depends on where the wire runs—indoors, outdoors, or underground. Always select insulation that matches your environment for long-term reliability.
Solid vs. Stranded Copper Wire for 100 Amp Service
Solid copper wire consists of a single thick conductor, while stranded wire is made of multiple thin strands twisted together. For 100 amp service, stranded copper wire is usually preferred because it’s more flexible, easier to install, and resists vibration damage. Solid wire, however, is cheaper and provides slightly better conductivity over short distances. The key is matching your wire type to your installation—solid wire for permanent, straight runs and stranded wire for complex or flexible setups where bending is needed.
Underground 100 Amp Service Wire Size Requirements
If your 100 amp service runs underground, you need wire that’s rated for direct burial or placed inside a conduit. In most cases, #2 AWG copper wire is used for underground runs, as it compensates for both distance and environmental conditions. Underground wires face moisture, soil acidity, and temperature variations, so proper insulation is crucial. Use XHHW or USE-rated copper wire for maximum durability and protection. Always follow local building codes for burial depth and conduit requirements to prevent damage and ensure safety.
What Size Copper Wire for 100 Amp Sub Panel
When wiring a 100 amp sub panel, the same wire sizing rules apply as for a main panel. Generally, #4 AWG copper wire is used for short distances, while longer runs may require #3 or #2 AWG. The sub panel must have a dedicated ground wire and neutral bus properly isolated. Always calculate based on distance and voltage drop to maintain efficiency. The right copper wire ensures that your sub panel delivers stable power to circuits without overloading the system.
What Size Copper Wire for 100 Amp Sub Panel 100 Feet Away
If your 100 amp sub panel is located 100 feet away, it’s best to use #3 AWG copper wire. This thickness compensates for minor voltage drop while keeping your setup compliant with NEC standards. A smaller wire might technically work but could lead to inefficient energy use or overheating over time. Whether your sub panel is in a garage, basement, or separate structure, always size the wire for distance and load. Proper sizing ensures your electrical distribution remains consistent and safe.
What Size Copper Wire for 100 Amp Sub Panel 200 Feet Away
For a 100 amp sub panel 200 feet from the main service, #1 AWG copper wire is recommended. The increased thickness ensures proper voltage at the sub panel, even across a long distance. Undersized wire will cause voltage drop, which can shorten the lifespan of electrical devices. Additionally, if the sub panel feeds large appliances or HVAC systems, upsizing becomes even more critical. Investing in a thicker copper wire guarantees long-term reliability and avoids costly rewiring in the future.
Factors That Influence Wire Size Selection
Several factors determine the right copper wire size for 100 amp service, including distance, voltage, ambient temperature, and wire material. For instance, longer distances require thicker wires to minimize voltage drop. Higher ambient temperatures can also reduce a wire’s current-carrying capacity, meaning you may need to upsize. Additionally, the type of insulation and whether the installation is indoors or underground plays a role. Always consider these factors together before selecting your wire gauge to ensure performance and compliance with electrical standards.
The Effect of Ambient Temperature on Copper Wire Size
Ambient temperature can significantly impact wire performance. Higher temperatures increase electrical resistance, meaning wires can carry less current safely. The NEC provides temperature correction factors that adjust allowable ampacity based on temperature. For example, in areas above 86°F (30°C), you may need a thicker wire for the same current rating. Copper wire handles heat better than aluminum, but proper sizing remains crucial. When installing in attics, crawl spaces, or outdoor conduits, always consider local temperature conditions to avoid overheating.
Common Mistakes When Choosing Wire Size for 100 Amp Service
One of the most common mistakes when choosing copper wire for 100 amp service is ignoring distance and voltage drop. Many homeowners select wire solely based on amp rating, forgetting how far the wire will run. Others mix wire materials, such as using aluminum for one section and copper for another, which can lead to connection issues. Another mistake is failing to check local electrical codes. Always research, calculate accurately, and consult a licensed electrician to avoid costly and dangerous wiring errors.
How to Calculate the Right Wire Size for 100 Amp Service
Calculating the right wire size involves understanding load, distance, and voltage. Start with your amperage—100 amps—and your system voltage (120/240V). Then, determine the total wire length from the power source to the panel. Using a voltage drop calculator or NEC wire sizing table, find the correct gauge that keeps voltage drop under 3%. For example, a 100 amp, 200-foot run usually requires #1 AWG copper wire. This calculation ensures your wiring is both safe and efficient, avoiding electrical losses.
What Happens If You Use the Wrong Wire Size for 100 Amp Service
Using the wrong wire size can have serious consequences. If the wire is too small, it can overheat, melt insulation, and even cause electrical fires. Undersized wires also lead to excessive voltage drops, damaging sensitive appliances. On the other hand, oversizing the wire unnecessarily increases material costs and makes installation harder. The goal is to find the perfect balance between efficiency, safety, and cost. Always follow NEC recommendations and verify your installation with a licensed electrician.
Comparing Copper and Aluminum Wires for 100 Amp Panels
Copper and aluminum wires each have pros and cons for 100 amp panels. Copper offers better conductivity, less expansion, and stronger connections, making it the safer, more reliable choice. Aluminum is lighter and cheaper but requires larger gauge sizes to carry the same current. Additionally, aluminum is more prone to oxidation, which can create loose connections and fire hazards over time. While copper costs more upfront, its long-term stability and low maintenance make it the preferred option for residential use.
What Size Copper Wire for 100 Amp 240V Circuit
For a 240V, 100 amp circuit, #4 AWG copper wire is typically sufficient for short distances. However, if the run exceeds 100 feet, upsizing to #3 or #2 AWG is recommended to minimize voltage drop. Since 240V circuits often power heavy appliances like HVAC systems, stoves, or welders, consistent current delivery is crucial. Using the correct wire size ensures these appliances operate efficiently without overheating or voltage fluctuations. Always confirm your wire size with local codes and load requirements.
What Size Copper Wire for 100 Amp 120V Circuit
A 120V, 100 amp circuit is less common but may be used for specialized equipment or certain industrial setups. Because lower voltage requires higher current for the same power output, thicker wire is needed. Typically, #3 AWG copper wire is recommended for short distances, while #2 AWG or even #1 AWG may be needed for longer runs. Always calculate voltage drop and consult an electrician when working with 120V circuits carrying high amperage, as improper sizing can lead to energy waste and overheating.
Best Practices for Installing 100 Amp Service Wire
When installing copper wire for a 100 amp service, following best practices is essential for both safety and performance. Start by ensuring the power is turned off and all equipment is properly grounded. Use approved connectors and fittings to prevent loose connections. Avoid sharp bends or kinks in the wire, as they can cause damage or reduce conductivity. Always follow NEC guidelines for conduit size, burial depth, and distance from other utilities. Taking these steps ensures your installation remains safe and compliant for years.
Safety Tips When Handling Copper Wire for 100 Amp Systems
Handling copper wire for high-amperage systems requires strict attention to safety. Always wear insulated gloves and use tools rated for electrical work. Never handle live wires, and double-check that power sources are disconnected before working. Be mindful of sharp wire ends and heavy rolls that can cause physical injury. Label circuits clearly, and follow color codes for hot, neutral, and ground wires. Finally, if you’re uncertain about any step, consult a licensed electrician—safety should always come before cost-cutting.
Tools Needed to Install Copper Wire for 100 Amp Service
Installing copper wire for 100 amp service requires a few essential tools. You’ll need a wire cutter, wire stripper, torque screwdriver, conduit bender, and voltage tester. For long runs, a fish tape helps pull the wire through conduits. A multimeter is also handy for checking voltage and continuity after installation. Don’t forget protective gear like gloves and safety goggles. Having the right tools not only ensures a professional-quality job but also minimizes installation time and safety risks.
What Size Copper Wire for 100 Amp Main Breaker
The main breaker is where the service line connects to your panel, and it must handle the full 100 amps. For this, #4 AWG copper wire is standard for short runs, while #3 or #2 AWG may be necessary for longer distances. Using the correct wire size ensures that the breaker can operate safely without overheating. Always double-check the manufacturer’s specifications for your breaker and follow NEC rules to guarantee compatibility and reliability.
What Size Copper Wire for 100 Amp Disconnect
A 100 amp disconnect switch is used to cut off power manually, typically for maintenance or safety reasons. The copper wire size used should match the main service wire—usually #4 AWG for short runs. If the disconnect is located farther from the panel, increase to #3 or #2 AWG. The goal is to maintain consistent current-carrying capacity throughout the system. Using smaller wire between the disconnect and panel can create weak links that compromise safety.
What Size Copper Wire for 100 Amp Feeder
A feeder line delivers electricity from one distribution panel to another. For a 100 amp feeder, the typical recommendation is #4 AWG copper wire for runs under 50 feet. If the distance increases, use #3 AWG or #2 AWG to counter voltage drop. Feeders often supply sub panels in garages, workshops, or detached buildings, so ensuring consistent voltage is essential. Always size feeders correctly based on total load, distance, and NEC code requirements to maintain system performance.
What Size Copper Wire for 100 Amp Service in a Detached Garage
For a detached garage, you’ll likely need to run a sub panel fed by your main service. The appropriate wire size depends on distance. For runs up to 100 feet, #3 AWG copper wire is ideal. If the garage is farther away—say 150 to 200 feet—use #2 or #1 AWG. The wire should be buried in a conduit at least 18 inches deep if underground. A proper ground rod system must also be installed to ensure safety and code compliance.
What Size Copper Wire for 100 Amp Service in a Workshop
Workshops often use heavy equipment, requiring stable and consistent power. For 100 amp service in a workshop, #4 AWG copper wire is sufficient for short distances. However, for longer runs or high-load tools, consider #3 AWG. Since workshops can generate heat and dust, it’s important to use insulated wires rated for tough conditions. Install conduit to protect wiring and always calculate load based on equipment requirements. This ensures safe, efficient operation without interruptions or equipment damage.
What Size Copper Wire for 100 Amp Service in a Mobile Home
Mobile homes typically require durable, code-compliant wiring systems. A 100 amp service for a mobile home often uses #4 AWG copper wire, but the size can vary with distance. NEC Article 550 covers specific rules for manufactured housing. You’ll also need a properly rated disconnect and grounding system. Because mobile homes may be relocated, flexible connections and weatherproof enclosures are recommended. Always check local and state regulations before installation to ensure safety and compliance.
What Size Copper Wire for 100 Amp Service in a Barn
A barn installation often involves longer runs and exposure to varying weather conditions. For a 100 amp service in a barn, #2 AWG copper wire is commonly used, especially if the run exceeds 100 feet. Since barns can have high humidity and fluctuating temperatures, use wire with moisture-resistant insulation such as XHHW. It’s also important to protect the wire in conduit and install grounding rods to prevent electrical shock hazards. Proper sizing ensures safety for lighting, fans, and equipment.
What Size Copper Wire for 100 Amp Service in a Shed
If your shed requires a 100 amp service—for example, to power tools, lights, and outlets—wire sizing depends on how far it is from the main service. For a short run, #4 AWG copper works fine; for 150 to 200 feet, #2 AWG is better. Ensure the wire is buried in conduit if underground and properly grounded. Oversizing slightly is a smart move for future upgrades, ensuring that your shed can handle additional electrical loads safely.
What Size Copper Wire for 100 Amp Service for a Sub Panel in the Basement
Basements often have sub panels to distribute power to various parts of a home. For a 100 amp sub panel in the basement, #4 AWG copper wire usually works since distances are short. The wire should be protected in conduit to avoid moisture exposure. Because basements can have higher humidity levels, ensure that all connections are tight and corrosion-resistant. This setup ensures reliable power flow to your lower-level circuits and prevents overheating or electrical faults.
What Size Copper Wire for 100 Amp Service for Outdoor Installation
Outdoor installations face unique challenges like weather, temperature swings, and moisture. For a 100 amp outdoor service, #2 AWG copper wire is typically used for longer runs. Choose insulation types like THWN-2 or XHHW-2, which are rated for wet and hot environments. Use PVC or metal conduit for protection and proper burial depth if underground. Always follow NEC and local code guidelines for outdoor installations to ensure longevity and prevent corrosion or electrical failures.
Can You Use #2 AWG Copper for 100 Amp Service?
Yes, #2 AWG copper wire can handle 100 amps easily and is often used when longer distances or voltage drop are concerns. It provides an added safety margin compared to #4 AWG. Many electricians prefer #2 AWG for sub panels located far from the main service because it maintains voltage more effectively. Although slightly more expensive, #2 AWG ensures your system runs cooler and lasts longer, making it a worthwhile investment in electrical safety.
Can You Use #3 AWG Copper for 100 Amp Service?
#3 AWG copper wire can be used for 100 amp service under specific conditions, such as shorter distances (less than 100 feet). It offers a balance between cost and performance, providing sufficient capacity while avoiding unnecessary bulk. However, for longer runs, upsizing to #2 or #1 AWG is safer. Always verify ampacity charts and voltage drop calculators before deciding, as factors like ambient temperature and insulation type can influence the final choice.
What Size Copper Wire for 100 Amp 3-Phase System
In a 3-phase system, current is distributed across three wires, reducing load per wire. For 100 amps in a 3-phase setup, #6 AWG copper wire can suffice for short runs, but most electricians prefer #4 AWG for added safety. Voltage, phase configuration, and distance affect the final size. Always consult NEC tables for 3-phase ampacity ratings. Since 3-phase systems are common in commercial or industrial setups, precision in wire sizing ensures balanced loads and efficiency.
What Size Copper Wire for 100 Amp Single Phase System
Single-phase systems are more common in residential settings. For a 100 amp single-phase service, #4 AWG copper wire is standard for runs under 50 feet. If the distance increases, upsizing to #3 or #2 AWG is necessary to manage voltage drop. Since all current flows through a single path, correct sizing prevents overheating and energy loss. Following NEC ampacity guidelines ensures that your single-phase installation remains both efficient and code-compliant.
Upgrading from 60 Amp to 100 Amp Service: Wire Size Considerations
When upgrading from a 60 amp service to a 100 amp service, wire size becomes one of the most critical factors. Older homes with 60 amp service typically use smaller wire gauges that cannot safely handle 100 amps. To upgrade, you’ll need to replace the existing wire with at least #4 AWG copper or #2 AWG aluminum. It’s also essential to upgrade the service panel, meter base, and breaker to accommodate the higher amperage. This ensures your home can handle modern electrical loads safely and efficiently without risking overheating or electrical faults.
What Size Copper Wire for 100 Amp Meter Base
The meter base is the point where your electrical service connects to the utility supply, and it must be properly rated for 100 amps. The recommended wire size for a 100 amp meter base is #4 AWG copper wire. However, if the distance between the meter base and panel exceeds 100 feet, upgrading to #3 or #2 AWG is wise. A properly sized wire prevents power loss and ensures accurate meter readings. Always use weather-resistant insulation when wiring outdoor meter bases to withstand environmental exposure.
Local Code Requirements for 100 Amp Service Wire Size
While the NEC provides national guidelines, local electrical codes may have additional requirements based on climate, soil type, and building standards. Some municipalities may require larger wire sizes for long runs or high-temperature areas. Always check with your local building department before purchasing materials. Using the correct wire size according to local regulations not only ensures safety but also simplifies inspections and approvals. Compliance with both NEC and local codes guarantees your installation is safe, legal, and long-lasting.
Cost of Copper Wire for 100 Amp Service Installation
The cost of copper wire varies based on gauge, length, and market prices for copper. As of recent trends, #4 AWG copper wire may cost around $2.50 to $3.50 per foot, while #2 AWG can reach $4 to $5 per foot. The total project cost depends on the run distance, insulation type, and whether the installation is above or below ground. While copper is more expensive than aluminum, its durability, conductivity, and reliability make it a long-term investment that reduces future maintenance and energy losses.
How to Future-Proof Your Electrical Setup with the Right Wire Size
If you’re installing or upgrading a 100 amp service, it’s wise to plan for future electrical demands. With the increasing use of EV chargers, HVAC systems, and smart home devices, sizing your wire slightly larger—such as using #2 AWG instead of #4—can prevent future rewiring costs. A thicker copper wire provides room for expansion and keeps voltage consistent even with additional loads. Think of it as future-proofing your electrical infrastructure, ensuring your system can adapt as your energy needs grow over time.
Conclusion
Selecting the correct copper wire size for a 100 amp service is one of the most important steps in designing a safe and efficient electrical system. Copper’s superior conductivity, heat resistance, and durability make it the top choice for residential and commercial setups alike. Whether your panel is in the basement, garage, or outdoors, considering factors like distance, voltage drop, and environment ensures the right gauge choice. Remember—#4 AWG copper wire is typically standard, but for longer runs, upsizing to #2 AWG offers added safety. Always verify your installation with local codes and, when in doubt, consult a licensed electrician. Doing it right the first time saves money, energy, and ensures lasting peace of mind.
FAQs
1. What is the standard wire size for 100 amp copper service?
The standard size is #4 AWG copper wire for short distances under 50 feet. For longer runs, you may need #3 or #2 AWG to prevent voltage drop.
2. Can I use aluminum wire instead of copper for 100 amp service?
Yes, but aluminum requires larger wire sizes—typically #2 AWG aluminum for 100 amps. Always apply anti-oxidant compound and torque connections properly to prevent corrosion.
3. How far can you run 100 amp service with copper wire?
You can run 100 amp service up to 100 feet with #3 AWG copper. For 200 feet or more, #1 AWG copper is recommended to maintain voltage efficiency.
4. Do I need a ground wire for 100 amp service?
Yes, grounding is essential. A #8 AWG copper ground wire is usually sufficient for 100 amp systems. This ensures electrical safety and prevents shock hazards.
5. Is it okay to oversize copper wire for a 100 amp service?
Absolutely. Oversizing slightly (e.g., using #2 AWG instead of #4 AWG) improves efficiency, reduces voltage drop, and prepares your system for future load increases.
6. What type of insulation should I use for 100 amp copper wire?
The best insulation types for 100 amp copper wire are THHN, THWN-2, or XHHW-2, depending on where you’re installing the wire. THHN works great for dry, indoor environments, while THWN-2 and XHHW-2 are ideal for outdoor or wet locations because they provide better heat and moisture resistance. Always match the insulation to the environment to ensure safety and longevity.
7. Can I run 100 amp service underground using copper wire?
Yes, you can run 100 amp service underground with copper wire, but it must be rated for direct burial or installed in a conduit. For underground runs, USE-2 or XHHW-2 copper wire types are recommended. The burial depth should typically be at least 18 to 24 inches, depending on local codes. Proper waterproofing and conduit sealing prevent corrosion and ensure a long-lasting installation.
8. How do I calculate voltage drop for a 100 amp copper wire?
To calculate voltage drop, use the formula:Voltage Drop (V) = (2 × K × I × D) / CM,
where K is the resistance constant for copper (12.9 ohms per mil-foot), I is current, D is distance (one-way), and CM is circular mil area of the wire. A simpler way is to use an online voltage drop calculator. Keeping voltage drop under 3% ensures efficiency and protects sensitive electronics from power fluctuations.
9. Is copper wire better than aluminum for 100 amp outdoor service?
Yes, copper is generally better than aluminum for outdoor 100 amp service because it resists corrosion, carries current more efficiently, and has a longer lifespan. Aluminum is lighter and cheaper but expands and contracts more with temperature changes, which can loosen connections. If you choose aluminum, ensure all terminations are approved for AL wire and apply anti-oxidant paste to reduce corrosion risks.
10. Can I connect copper and aluminum wires together in a 100 amp circuit?
Yes, but it must be done carefully using connectors rated for both copper and aluminum (CU/AL). Never twist them together directly, as it can cause corrosion and high resistance. Use approved lugs or splice connectors, apply anti-oxidant compound, and torque them properly. Mixing metals without proper connectors is a common cause of overheating and electrical fires, so always follow NEC and manufacturer guidelines.
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