Wire Size Calculator

Estimate recommended AWG wire gauge using current, voltage, one-way distance, conductor material, phase, and allowable voltage drop. Useful for controls panels, machine wiring, field devices, motors, and general electrical design work.

Open Calculator Voltage Drop Calculator
Good starting use case: use this for quick conductor sizing during automation design, controls layout, and machine wiring review before finalizing the circuit against code, insulation temperature rating, bundling adjustments, ambient corrections, and installation details.
Calculator

Estimate Recommended Wire Size

Use this wire size calculator to estimate recommended AWG wire gauge based on current, voltage, distance, conductor material, phase, and acceptable voltage drop.

This tool is useful for automation systems, controls panels, motor circuits, field devices, and general electrical design where both ampacity and voltage drop matter.

Single-Phase / DC Voltage Drop ≈ 2 × Current × Resistance × Distance
Three-Phase Voltage Drop ≈ 1.732 × Current × Resistance × Distance

This calculator selects the smallest conductor that meets both ampacity and voltage drop target.
Quick examples
Enter values and press Calculate.

Need help applying this to a real machine?

Get connected with a qualified automation integrator if you need help with controls wiring, conductor sizing, panel design, or real-world electrical layout decisions.

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This calculator provides a practical engineering estimate and is not a substitute for NEC, local code, insulation temperature rating, bundling adjustments, ambient corrections, or final design review.

Final conductor size should always be checked against the actual installation method, temperature limits, startup current, terminal ratings, and applicable code requirements.

What to check next

This tool is excellent for a fast wire-size estimate, but final conductor selection depends on more than current and distance. Installation method, ambient temperature, bundling, insulation class, terminal temperature rating, and actual startup or inrush current can all change the correct answer.

For real electrical design, this page usually works best alongside voltage drop review and conductor reference charts so you can verify both circuit performance and practical installation limits.

Voltage Drop Calculator Wire Gauge vs Amps AWG Wire Gauge Chart Motor Full Load Current
Reference

Quick AWG Reference

AWG Area (mm²) Resistance Copper (Ω / 1000 ft) Typical Copper Ampacity
200.5210.155 A
180.826.397 A
161.314.0210 A
142.082.5315 A
123.311.5920 A
105.261.0030 A
88.370.6340 A
613.30.4055 A
421.10.2570 A
233.60.1695 A
142.40.13110 A
1/053.50.10125 A
2/067.40.08145 A
3/085.00.06165 A
4/01070.05195 A
Automation Engineering Tools • Practical calculators for real automation work

What this calculator gives you

  • Recommended AWG size
  • Estimated voltage drop
  • Estimated voltage drop percent
  • Estimated final voltage
  • Estimated power loss
  • Material and phase assumptions used

Where this helps

Useful for controls panels, machine wiring, field devices, motors, sensors, actuators, and early electrical design where both conductor size and delivered voltage matter.

Common next checks

  • NEC or local code compliance
  • Insulation temperature rating
  • Conductor bundling and ambient temperature
  • Startup or inrush current
  • Actual device minimum voltage requirement

Practical reminder

A wire that passes quick math can still be the wrong choice if the installation method, ambient conditions, or device voltage sensitivity are not considered.