4 AWG copper is a typical pick for 74.25A at 75 feet on 120V under a 3% drop target. It balances NEC branch-circuit ampacity and voltage drop over distance. Drop with 4 AWG at these inputs: 3.43V (2.86%). Real-world sizing also depends on insulation temperature rating, cable type, and install conditions.
74.25A at 75ft · 120V single-phase / DC · 3% drop target
4 AWG copper
Aluminum option2 AWG
On a 240V circuit (copper)4 AWG
Voltage drop (120V, copper)3.43V (2.86%)
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
4 AWG branch-circuit OCP (85A) ≥ 74.25A ✓
The conductor needs to carry at least 74.25A 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), 4 AWG sits at a branch-circuit OCP of 85A. That is not a universal number: NM-B cable (Romex) follows the 60°C column in residential use per NEC 334.80 (4 AWG NM-B = 70A), 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 6 AWG (one size thinner) at these inputs gives a voltage drop of 5.47V (4.56% on 120V), and its branch-circuit OCP cap under typical conditions is 65A.
Limiting factor here: branch-circuit ampacity. 6 AWG has a branch-circuit OCP cap of 65A under the typical 75°C-termination assumptions used here, which is below the 74.25A load. For this load it shouldn't be used without reassessing against the actual termination temperature, cable type, ambient conditions, and any 240.4(D) or 240.4(B) provisions.
What If You Go One Size Larger?
Using 3 AWG (one size thicker) would reduce voltage drop to 2.73V (2.27% on 120V). More expensive wire but better performance and more headroom for future load increases.
Wattage at This Amperage
74.25A at 120V delivers 8,910 watts (DC / resistive load). See conversion.
74.25A at 75ft on 120V is commonly served by 4 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 150ft 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 74.25A, 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.
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.
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.
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.
