![]() Careful attention should be given to insulation ratings, ampacity, voltage drop, conduit fill, and using properly rated connectors for a successful installation. Following the #3 AWG copper recommendations ensures a properly wired 100A circuit. ConclusionĬhoosing the optimal wire size and type for a 100 amp breaker involves numerous considerations for performance, protection, and code compliance. Larger wires reduce resistance and maintain voltage within acceptable levels at the outlet or equipment. ![]() Excessive drop can cause device problems. Minimizing Voltage Dropįor longer wire runs to a 100A breaker, consider upsizing wires one gauge to minimize voltage drop. Correct wire sizes, insulation, and installation method all impact achieving proper ampacity for the 100A rating. Ampacity denotes current carrying capacity. Size 100 amp breaker wires based on required ampacity and NEC guidelines to prevent undue heating. For the larger #3 wires, look for 100A compatible mechanical lug connectors or compression lugs rated for the wire size. Standard lugs may only be rated up to #4 AWG. Use properly rated lugs to terminate the wires at the 100A breaker. Look for the correct temperature, wet location, and other ratings needed for the installation. THWN-2 – can be used for wet or dry locations In addition to THHN, some other common insulations used with #3 copper wire for 100A breakers include: For code compliance, calculate the conduit fill percentages and adjust conduit sizes as needed. Typically, a 1″ conduit can fit three #3 THHN wires for a 100A 240V circuit. Running #3 AWG THHN wires through conduit needs to consider conduit fill requirements. A larger size helps compensate for heat buildup in the buried cable. For aluminum, increase to #1/0 AWG underground. For copper wire, the recommended size is #3 AWG based on the 75☌ ampacity. Underground wiring to a 100A breaker should use the proper underground rated wire like USE-2 or UF. Oversize aluminum to #1/0 AWG for better performance. Common insulated aluminum conductors would be #1 XHHW-2 or #1 RHH/RHW-2 for wet locations. This requires #1 AWG aluminum wire to match the capacity of #3 copper. The code allows aluminum wires for 100A breakers following the NEC one size rule. Optional larger sizes like #2 or #1 AWG can be used for less voltage drop. This gauge handles 100A for installations including wiring in: Copper Wire Sizesįor a 100A breaker, the NEC recommends #3 AWG copper wire. This allows it to be safely run through conduit. THHN wire size for 100 amps would be the standard #3 AWG copper softened with THHN insulation. This high heat-resistant thermoplastic wiring stands up to the elevated temperatures that can occur in a 100A circuit. THHN Wire for 100 Amp BreakersĪ common wire insulation type used with 100 amp breakers is THHN wire. Oversizing beyond the code minimum is unnecessary and increases expense. Smaller wires may overheat, melt or cause voltage drops. This wire gauge is sized to safely handle the 100A current and prevent overload conditions from occurring. The chart includes values for both copper wire and aluminum wire. The National Electrical Code (NEC) minimum wiring size for a 100 amp breaker is #3 AWG copper or #1 AWG aluminum. The 100 Amp Wire Size Chart provides information on the recommended wire sizes for different amperage ratings and maximum distances for a 3 voltage drop.
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