Wire Gauge Calculator

Enter the Wave Sources, Wavelength, Slit Separation, and Screen Distance into the Interference Calculator to find Fringe Spacing, Path Difference, Constructive/Destructive positions, and Intensity Pattern.

A

The current draw of your load in amperes

ft

Distance from power source to load

%

Acceptable voltage drop percentage (typically 3-5%)

Results

Recommended Wire Size

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Required Circular Mils

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Actual Voltage Drop

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Wire Cross Section

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Power Loss

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Voltage Distribution

Frequently Asked Questions

How do you calculate wire size?

Wire size is calculated using Ohm's law and Pouillet's law, considering current load, voltage, distance, and acceptable voltage drop. The formula accounts for conductor resistivity and cross-sectional area needed to carry current safely within voltage drop limits.

How do I calculate wire size for 12V DC systems?

For 12V DC systems, use higher current values and consider voltage drop more carefully due to lower system voltage. DC circuits require larger wire sizes than AC for the same power due to the constant current flow and lack of RMS benefits.

What's the difference between copper and aluminum wire sizing?

Aluminum has higher resistance than copper, requiring larger wire sizes for the same current capacity. Aluminum is about 61% as conductive as copper, so you typically need to go up 1-2 AWG sizes when using aluminum instead of copper.

How do I calculate AWG wire size for long distances?

For long distances, voltage drop becomes the primary concern rather than ampacity. Calculate the circular mils needed using the distance, current, and acceptable voltage drop, then select the nearest standard AWG size that meets or exceeds this requirement.

What voltage drop percentage should I use?

The National Electrical Code recommends maximum 3% voltage drop for branch circuits and 5% total for the entire system. For sensitive electronics or motor applications, consider limiting voltage drop to 2-3% for optimal performance.

How does temperature affect wire size calculations?

Higher operating temperatures reduce wire ampacity due to increased resistance and insulation limitations. Wire rated for 90°C can carry more current than the same wire rated for 60°C, affecting the size selection for your application.

Do I need different calculations for single-phase vs three-phase?

Yes, three-phase systems are more efficient and require different calculations. Three-phase circuits use a factor of √3 (1.732) in calculations and typically require smaller wire sizes than single-phase for the same power delivery.

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