250 kcmil copper is a typical pick for 162.5A at 200 feet on 120V under a 3% drop target. It balances NEC branch-circuit ampacity and voltage drop over distance. Drop with 250 kcmil at these inputs: 3.35V (2.79%). Real-world sizing also depends on insulation temperature rating, cable type, and install conditions.
162.5A at 200ft · 120V single-phase / DC · 3% drop target
250 kcmil copper
Aluminum option500 kcmil
On a 240V circuit (copper)2/0 AWG
Voltage drop (120V, copper)3.35V (2.79%)
Use this citation when referencing this page.
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Within the 3% branch and 5% feeder+branch total drop targets
Assumes a 120V source on a single-phase / DC circuit and a 3% voltage-drop target. Each material is picked independently against the same target, so the copper and aluminum results are two separate recommendations, not an ampacity equivalence. Switch to three-phase L-L →
How Wire Size Is Determined
Step 1: NEC Branch-Circuit Ampacity
250 kcmil branch-circuit OCP (255A) ≥ 162.5A ✓
The conductor needs to carry at least 162.5A without going past its temperature rating, and the OCP protecting it needs to respect the NEC branch-circuit cap. Under the typical assumptions used in this table (copper, 75°C termination, no bundling or ambient derates), 250 kcmil sits at a branch-circuit OCP of 255A. That is not a universal number: NM-B cable (Romex) follows the 60°C column in residential use per NEC 334.80 (250 kcmil NM-B = 215A), bundling more than three current-carrying conductors requires a 310.15(C)(1) adjustment, ambient temperatures above 30°C require a 310.15(B) correction, and 60°C terminations on typical residential equipment can pull the usable value lower still. Use the nameplate and local code for the actual install value.
Step 2: Voltage Drop Check
%VD = (2 × L × I × R) ÷ (1000 × V) × 100 (single-phase / DC; round-trip factor of 2)
NEC 210.19(A) Informational Note 4 recommends ≤ 3% for branch circuits and ≤ 5% for feeder + branch total as performance targets, not hard code requirements. This run sits within the 3% target used for this calculation.
Practical Information
What If You Go One Size Smaller?
Using 4/0 AWG (one size thinner) at these inputs gives a voltage drop of 3.95V (3.29% on 120V), and its branch-circuit OCP cap under typical conditions is 230A.
Limiting factor here: voltage drop, not ampacity. 4/0 AWG is still above the 162.5A load at its 230A branch-circuit OCP cap, so the conductor temperature margin is fine for this run. What pushes it off this page's pick is the 3.29% drop sitting past the 3% target, which is a performance recommendation (NEC 210.19(A) Informational Note 4), not a code requirement. On shorter runs or at higher source voltage the same gauge would often clear the drop target too.
What If You Go One Size Larger?
Using 300 kcmil (one size thicker) would reduce voltage drop to 2.79V (2.32% on 120V). More expensive wire but better performance and more headroom for future load increases.
Wattage at This Amperage
162.5A at 120V delivers 19,500 watts (DC / resistive load). See conversion.
162.5A at 200ft on 120V is commonly served by 250 kcmil copper to land under the 3% voltage-drop target, under the typical 75°C-termination assumptions used in this table. Actual install sizing also depends on conductor material, insulation and termination temperature rating, cable type, ambient and bundling conditions, and local code.
Voltage drop scales linearly with distance: doubling the one-way run length doubles the drop in volts. At 162.5A on 120V, a 200ft run is often served by 250 kcmil to land under the 3% drop target, a run half that length can sometimes use one gauge thinner, and a run double that length usually needs one or two gauges thicker. Ampacity is set by the conductor itself (Table 310.16 at the applicable termination temperature), so the binding constraint is ampacity on short runs and voltage drop on long runs.
Copper wire pricing tracks the LME copper spot price and varies with insulation type, cable assembly (THHN, NM-B, MC, SE, USE), and quantity. Check current pricing with a local electrical supply house or distributor catalog; commodity-driven numbers inlined on a calculator page age quickly.
Yes, but you may need thicker wire. At 400ft on 120V, check the wire size calculator. You may need to go up one or two gauges.
Copper and aluminum are picked independently against the same drop target on this site; neither pick implies ampacity equivalence with the other. At 162.5A, aluminum is the industry standard for sub-panel feeders, service entrance, and utility drops. AA-8000 series aluminum is the modern feeder material; copper is still used where space is tight or terminations are copper-only. Aluminum has lower conductivity than copper, so when each material is run through the drop-target pick independently, the aluminum result typically lands one to two gauges larger than the copper result for the same duty. That gap is the result of running both picks against the same drop-target constraint, not an ampacity-equivalence rule. The install still needs anti-oxidant compound and aluminum-rated lugs.
This calculator provides estimates for reference purposes only. Always consult a licensed electrician and verify compliance with the National Electrical Code (NEC) and local electrical codes before performing any electrical work.
