How to Determine the Proper Cable & Wire Size

for a Given Load?

Farhan Ahmad
Design Engineer
(Lv & Mv Switchgear)

Below are solved examples demonstrating how to find the proper cable size for a given load.
For a given load, cable size may be determined using various IEC and NEC tables (such Article
310 – Table – 310.15 (B) 16. However, it is crucial to keep in mind the role of ambient
temperature and voltage drop for distance between main panel and subpanel.
When determining the size of cable for a given load, take into account the following general
rules of thumbs.

 For a given load, apart from the known current value, there should be a 20% additional
margin as safety factor and for future or emergency needs (required by both NEC (220-2)
and IEC/IEEE).

 In the NEC – 316-10, add an additional 20% ampacity to the wire size if the length of the
wire exceeds 100 ft (between the main panel and the subpanel).

 In IEC, the voltage drop should be limited to 1.25%, and for the final sub-circuit, the voltage
drop should not exceed 2.5% of the supply voltage from the energy meter to the distribution
board.

 Consider the change in temperature, which affects the ampacity (current carrying capacity)
of the wire. When needed, use the temperature factor (Table 3 and related NEC table given
at the end of this article).

 Additionally, take the load factor (diversity factor or demand factor (NEC – 220.42 and
(220.45)) into consideration when determining the size of the cable.

 When calculating the cable size, consider the type of wiring system; for example, in an open
wiring system, temperature would be low, but in conduit wiring, temperature increases due
to the absence of air.
Solved Examples of Proper Cable & Wire Size
The following examples illustrate how to determine the proper size of cables for electrical
wiring installations. These examples will make it easy to understand the method of determining
the proper cable size for a given load in both single phase ad three phase wiring installations.

Example 2 – (240V and Distance Involved NEC)

Find the Proper wire size for 2,400 W load circuit supplied by 240V at a distance of 100 feet?

Solution:
Find the current using the following formula (same as mentioned above)
Current = Power ÷ Voltage
I = 2,400 W ÷ 240 V
I = 10 Amperes
Now, multiply the safety factor of 1.25 (80% of load should be connected of the rated ampacity)
to the calculated amperage.
I = 10 A x 1.25
I = 12.5 Amperes
As the circuit is 100ft away, add additional 20% capacity to the calculated value (according to
the NEC Code – 310-16) to counter the voltage drop in the circuit.
20% of 12.5A = 0.20A × 1.25A = 2.5A.
Total Amps = 12.5A + 2.5A = 15 Amperes.
According to NEC table 310-15B and AWG wire size chart, the suitable wire size for 15 amp
circuit is #14 AWG for copper at 60°C (140°F).

 Warning: It is always advisable to use copper wire instead of aluminum for better
conductivity and reduced power consumption. If it is necessary to use aluminum, the wire
size in AWG may differ compared to a copper conductor. Refer to the tables given below
to select the wire size accordingly in the case of using aluminum.
In addition, it is recommended to use solid wire instead of stranded wire for a better grip,
reduced sparks, and a protected environment from shock and fire.
Example 3 – (Imperial, British or English System)
For an electrical wiring installation in a building, where the total load is 4.5kW and the total
length of cable from the energy meter to the sub-circuit distribution board is 35 feet, with a
supply voltage of 220V and a temperature of 40°C (104°F), find the most suitable size of cable
if wiring is installed in conduits.

Solution:
 Total Load = 4.5kW = 4.5 x 1000W = 4500W
 20% additional load = 4500 x (20/100) = 900W
 Total Load = 4500W + 900W = 5400W
 Total Current = I = P ÷ V = 5400W /220V = 24.5A
Now select the size of cable for load current of 24.5A (from Table 1) which is 7/0.036 (28
Amperes). It means we can use 7/0.036 cable according to table 1.
Now, check the selected (7/0.036) cable with the temperature factor in Table 3. The
temperature factor is 0.94 (from Table 3) at 40°C (104°F), and the current carrying capacity of
(7/0.036) is 28A. Therefore, the current carrying capacity of this cable at 40°C (104°F) would
be:
Current rating for 40°C (104°F) = 28 x 0.94 = 26.32 Amp.
Since the calculated value (26.32 Amp) at 40°C (104°F) is less than the current carrying
capacity of the (7/0.036) cable, which is 28A, this size of cable (7/0.036) is also suitable with
respect to temperature.
Now find the voltage drop for 100 feet for this (7/0.036) cable from Table 4 which is 7V, But
in our case, the length of cable is 35 feet. Therefore, the voltage drop for 35 feet cable would
be;
Actual Voltage drop for 35 feet = (7 x 35/100) x (24.5/28) = 2.1V
And Allowable voltage drop = (2.5 x 220)/100 = 5.5V
Here, the actual voltage drop (2.1V) is less than the maximum allowable voltage drop of 5.5V.
Therefore, the most appropriate and suitable cable size for that given load in the electrical
wiring installation is (7/0.036).
Related Posts:
Example 4 – (SI / Metric / Decimal System)
What type and size of cable suits for given situation
 Load = 5.8kW
 Volts = 230V AV
 Length of Circuit = 35 meter
 Temperature = 35°C (95°F)

Solution:
Load = 5.8kW = 5800W
Voltage = 230V
Current = I = P/V = 5800 / 230 = 25.2A
20% additional load current = (20/100) x 5.2A = 5A
Total Load Current = 25.2A + 5A = 30.2A
Now select the size of cable for load current of 30.2A (from Table 1) which is 7/1.04 (31
Amperes). It means we can use 7/0.036 cable according to the table 1.
Now check the selected (7/1.04) cable with temperature factor in Table 3, so the temperature
factor is 0.97 (in table 3) at 35°C (95°F) and current carrying capacity of (7/1.04) is 31A,
therefore, current carrying capacity of this cable at 40°C (104°F) would be;
Current rating for 35°C (95°F) = 31 x 0.97 = 30 Amp.
Since the calculated value (30 Amp) at 35°C (95°F) is less than that of current carrying capacity
of (7/1.04) cable which is 31A, therefore this size of cable (7/1.04) is also suitable with respect
to temperature.
Now find the voltage drop for per ampere meter for this (7/1.04) cable from (Table 5) which is
7mV, But in our case, the length of cable is 35 meter. Therefore, the voltage drop for 35 meter
cable would be:
Actual Voltage drop for 35meter =
= mV x I x L
= (7/1000) x 30×35 = 7.6V
And Allowable voltage drop = (2.5 x 230)/100 = 5.75V
Here the actual Voltage drop (7.35V) is greater than that of maximum allowable voltage drop
of 5.75V. Therefore, this is not a suitable size of cable for that given load. So we will select the
next size of selected cable (7/1.04) which is 7/1.35 and find the voltage drop again.
According to Table (5) the current rating of 7/1.35 is 40 Amperes and the voltage drop in per
ampere meter is 4.1 mV (See table (5)). Therefore, the actual voltage drop for 35 meter cable
would be;
Actual Voltage drop for 35 meter =
= mV x I x L
(4.1/1000) x 40×35 = 7.35V = 5.74V
This drop is less than that of maximum allowable voltage drop. So this is the most appropriate
and suitable cable or wire size.

Example 5
Following Loads are connected in a building:-
Sub-Circuit 1
 2 lamps each o 1000W and
 4 fans each of 80W
 2 TV each of 120W

Sub-Circuit 2
 6 Lamps each of 80W and
 5 sockets each of 100W
 4 lamps each of 800W

If supply voltages are 230 V AC, then calculate circuit current and Cable size for each
Sub-Circuit?

Solution:
Total load of Sub-Circuit 1
= (2 x 1000) + (4 x 80) + (2×120)
= 2000W + 320W + 240W = 2560W
Current for Sub-Circuit 1 = I = P/V = 2560/230 = 11.1A
Total load of Sub-Circuit 2
= (6 x 80) + (5 x 100) + (4 x 800)
= 480W + 500W + 3200W= 4180W
Current for Sub-Circuit 2 = I = P/V = 4180/230 = 18.1A
Therefore, Cable suggested for sub circuit 1 = 3/.029” (13 Amp) or 1/1.38 mm (13 Amp)
Cable suggested for Sub-Circuit 2 = 7/.029” (21 Amp) or 7/0.85 mm (24 Amp)
Total Current drawn by both Sub-Circuits = 11.1A + 18.1A = 29.27 A
So cable suggested for Main-Circuit = 7/.044″ (34 Amp) or 7/1.04 mm (31 Amp)

Example 6
A 10H.P (7.46kW) three phase squirrel cage induction motor of continuous rating using Star-
Delta starting is connected through 400V supply by three single core PVC cables run in
conduit from 250feet (76.2m) away from multi-way distribution fuse board. Its full load
current is 19A. Average summer temperature in Electrical installation wiring is 35°C (95°F).
Calculate the size of the cable for the motor?

Solution:

Motor load = 10H.P = 10 x 746 = 7460W *(1H.P = 746W)

Supply Voltage = 400V (3-Phase)
Length of cable = 250feet (76.2m)
Motor full load Current = 19A
Temperature factor for 35°C (95°F) = 0.97 (From Table 3)
Now select the size of cable for full load motor current of 19A (from Table 4) which is
7/0.36” (23 Amperes) *(Remember that this is a 3-phase system i.e. 3-core cable) and the
voltage drop is 5.3V for 100 Feet. It means we can use 7/0.036 cable according Table (4).
Now check the selected (7/0.036) cable with temperature factor in table (3), so the
temperature factor is 0.97 (in table 3) at 35°C (95°F) and current carrying capacity of
(7/0.036”) is 23 Amperes, therefore, current carrying capacity of this cable at 40°C (104°F)
would be:
Current rating for 40°C (104°F) = 23 x 0.97 = 22.31 Amp.

Since the calculated value (22.31 Amp) at 35°C (95°F) is less than that of current carrying
capacity of (7/0.036) cable which is 23A, therefore this size of cable (7/0.036) is also suitable
with respect to temperature.
Load factor = 19/23 = 0.826
Now find the voltage drop for 100feet for this (7/0.036) cable from table (4) which is 5.3V,
But in our case, the length of cable is 250 feet. Therefore, the voltage drop for 250 feet cable
would be;
Actual Voltage drop for 250feet = (5.3 x 250/100) x 0.826 = 10.94V
And maximum Allowable voltage drop = (2.5/100) x 400V= 10V
Here the actual Voltage drop (10.94V) is greater than that of maximum allowable voltage
drop of 10V. Therefore, this is a not a suitable size of cable for the given load. So we will
select the next size of selected cable (7/0.036) which is 7/0.044 and find the voltage drop
again. According to Table (4) the current rating of 7/0.044 is 28 Amperes and the volt drop in
per 100 feet is 4.1V (see Table 4). Therefore, the actual voltage drop for 250 feet cable would
be;
Actual Voltage drop for 250 feet =
= Volt drop per 100 feet x length of cable x load factor
= (4.1/100) x 250 x 0.826 = 8.46V
And Maximum Allowable voltage drop = (2.5/100) x 400V= 10V
The actual voltage drop is less than that of maximum allowable voltage drop. So this is the
most appropriate and suitable cable size for electrical wiring installation in a given situation.
NEC Wire Size Table 310.15(B)(16) (formerly Table 310.16) &
Chart
NEC (National Electrical Code) Table 310.15(B)(16) (formerly Table 310.16) – 310.60 –
ARTICLE 310 – Conductors for General Wiring & Allowable Ampacities of Conductors &
Wire Sizes based on AWG (American Wire Gauge).
310.60 ARTICLE 310 — CONDUCTORS FOR GENERAL WIRING

Table 310.15(B)(16) (formerly Table 310.16) Allowable Ampacities of Insulated Conductors Rated Up
to and Including 2000 Volts, 60°C Through 90°C (140°F Through 194°F), Not More Than Three
Current-Carrying Conductors in Raceway, Cable, or Earth (Directly Buried), Based on Ambient
Temperature of 30°C (86°F)*

Temperature Rating of Conductor [See Table 310.104(A).]

60°C 75°C 90°C 60°C 75°C Size

Size 90°C (194°F)
(140°F) (167°F) (194°F) (140°F) (167°F) AWG
AWG or
or
kcmil Types Types Types Types
TW, RHW, TBS,
Types TW,
RHW,
Types TBS, SA, SIS, kcmil
UF THHN, THHW,
UF THHW, SA, THHW,
 THW, SIS, THW, THW-2, THWN-2,
THWN, FEP, THWN,
XHHW, FEPB, XHHW, RHH, RHW-2, USE-
USE, MI, USE 2, XHH, XHHW,
ZW RHH,
RHW-2, XHHW-2, ZW-2
THHN,
THHW,
THW-2,
THWN-
2, USE-
2, XHH,
XHHW,
XHHW-
2, ZW-2

COPPER ALUMINUM OR COPPER-CLAD ALUMINUM

18** — — 14 — — — —

16** — — 18 — — — —

14** 15 20 25 — — — —

12** 20 25 30 15 20 25 12**

10** 30 35 40 25 30 35 10**

8 40 50 55 35 40 45 8

6 55 65 75 40 50 55 6

4 70 85 95 55 65 75 4

3 85 100 115 65 75 85 3

2 95 115 130 75 90 100 2

1 110 130 145 85 100 115 1

1/0 125 150 170 100 120 135 1/0

2/0 145 175 195 115 135 150 2/0

3/0 165 200 225 130 155 175 3/0

 4/0 195 230 260 150 180 205 4/0

250 215 255 290 170 205 230 250

300 240 285 320 195 230 260 300

350 260 310 350 210 250 280 350

400 280 335 380 225 270 305 400

500 320 380 430 260 310 350 500

600 350 420 475 285 340 385 600

700 385 460 520 315 375 425 700

750 400 475 535 320 385 435 750

800 410 490 555 330 395 445 800

900 435 520 585 355 425 480 900

1000 455 545 615 375 445 500 1000

1250 495 590 665 405 485 545 1250

1500 525 625 705 435 520 585 1500

1750 545 650 735 455 545 615 1750

2000 555 665 750 470 560 630 2000

 *Refer to 310.15(B)(2) for the ampacity correction factors where the ambient temperature is other
than 30°C (86°F). Refer to 310.15(B)(3)(a) for more than three current-carrying conductors.
 **Refer to 240.4(D) for conductor overcurrent protection limitations.

Here is the NEC table as a chart (image format to downloads as a reference)