What Wire Size for 25.47 Amps at 400 Feet?

1 AWG copper is a typical pick for 25.47A at 400 feet on 120V under a 3% drop target. It balances NEC branch-circuit ampacity and voltage drop over distance. Drop with 1 AWG at these inputs: 3.14V (2.61%). Real-world sizing also depends on insulation temperature rating, cable type, and install conditions.

25.47A at 400ft · 120V single-phase / DC · 3% drop target
1 AWG copper
On a 240V circuit (copper)4 AWG
Voltage drop (120V, copper)3.14V (2.61%)

No aluminum row: every aluminum size in our reference table sits past the 3% drop target at 400 feet on 120V, or the amperage is below the 30A residential threshold where aluminum is not a typical pick. On a higher source voltage, a shorter run, or a looser drop target, aluminum is still the standard feeder material at higher amperages.

check_circle Within the 3% branch and 5% feeder+branch total drop targets
1 AWG Cu

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

1 AWG branch-circuit OCP (130A) ≥ 25.47A ✓

The conductor needs to carry at least 25.47A 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), 1 AWG sits at a branch-circuit OCP of 130A. That is not a universal number: NM-B cable (Romex) follows the 60°C column in residential use per NEC 334.80 (1 AWG NM-B = 110A), 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)

(2 × 400 × 25.47 × 0.154) ÷ (1000 × 120) × 100 = 2.61%

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 2 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 115A.

Limiting factor here: voltage drop, not ampacity. 2 AWG is still above the 25.47A load at its 115A 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 1/0 AWG (one size thicker) would reduce voltage drop to 2.49V (2.07% on 120V). More expensive wire but better performance and more headroom for future load increases.

Wattage at This Amperage

25.47A at 120V delivers 3,056.4 watts (DC / resistive load). See conversion.

Related Calculations

trending_down V-drop: 1 AWG, 25.47A, 400ft electric_bolt 25.47A to watts at 120V functions Wire sizing formula

Frequently Asked Questions

25.47A at 400ft on 120V is commonly served by 1 AWG 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.
Yes, but you may need thicker wire. At 800ft on 120V, check the wire size calculator. You may need to go up one or two gauges.
NEC 210.19(A) Informational Note 4 recommends ≤3% for branch circuits and ≤5% total (feeder + branch). These are performance recommendations, not hard code requirements.
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.
Voltage drop scales linearly with distance: doubling the one-way run length doubles the drop in volts. At 25.47A on 120V, a 400ft run is often served by 1 AWG 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.
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.
person Written by Sean Day verified Reviewed by WireResult update Last updated Apr 11, 2026