Cable Knowledge
What Cable Size Do I Need for My Load Current?
Questions such as 'what cable size for 100 amps?' do not have one universal answer. The same current may require different conductors depending on installation, ambient conditions, route length, insulation and local code.
Continuous Current Capacity
Start with the design current and an ampacity method accepted by the project. Cable tables assume defined installation and temperature conditions. Correction factors are applied when the real conditions differ.
Grouped loaded cables, thermal insulation, high ambient temperature and poor soil heat dissipation can significantly reduce capacity.
Voltage Drop
Long routes can require a larger conductor even when thermal ampacity is adequate. Check steady-state drop and, for motors, starting performance. Power factor and conductor reactance can matter on larger AC circuits.
Fault and Protection Checks
The conductor and protective conductor must withstand the expected fault energy until the protective device clears it. The device must also disconnect within the required time and protect the cable against overload.
Data Needed for a Calculation
- Load current and load type
- Voltage, phase and frequency
- One-way route length
- Installation method and ambient conditions
- Number of grouped circuits
- Fault level, clearing time and voltage-drop limit
Why a 100 A Answer Can Differ
A short copper feeder on open tray, a long feeder in a hot grouped conduit and a buried aluminium feeder may all carry 100 A but need different sizes. Ampacity may govern the first case, voltage drop the second, and installation or fault duty the third.
- Calculate, do not select from current alone.
- Use the same code basis for tables and correction factors.
- Document the limiting check.
Information to Confirm
- Design current and duty cycle
- Route length and permitted voltage drop
- Cable arrangement and grouping
- Ambient air or soil conditions
- Protection device and fault data
- Local code and project standard
Engineering note: Use a qualified designer for final sizing; online rules of thumb are not a substitute for a documented calculation.
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