This is the most misquoted number in residential wire sizing. In NEC Table 310.16, 4/0 AWG aluminum is rated 180 A at 75°C — not enough for a 200-amp circuit. 4/0 aluminum is nevertheless the standard 200-amp residential service conductor, and both facts are correct, because two different rules apply:
| Application | Governing rule | Aluminum for 200 A |
|---|---|---|
| Dwelling service entrance, or the feeder carrying the entire dwelling load | NEC 310.12 (the “83% rule”) | 4/0 AWG |
| Everything else — sub-panel feeders, commercial feeders, branch circuits | NEC Table 310.16 | 250 kcmil |
NEC 310.12 permits service and main-power feeder conductors for a one-family dwelling to be sized at 83% of the service rating: 200 A × 0.83 = 166 A, and 4/0 aluminum’s 180 A rating covers that. The allowance exists because a dwelling never draws its full service rating continuously. It applies only to the conductors carrying the entire dwelling load.
For a 200-amp sub-panel feeder to a garage or shop, a commercial feeder, or any circuit that is not the dwelling’s main power feeder, 310.12 does not apply and you need 250 kcmil aluminum (205 A at 75°C). Copper is 4/0 AWG (230 A) in either case.
Residential service entrance, commercial feeders
| Diameter | 11.684 mm (0.46") |
| Area | 107.2193 mm² |
| Resistance at 20°C | 0.1608 Ω/km |
| Weight | 960.685 kg/km |
| Ampacity (75°C) | 230 A |
Important: For long wire runs, you may need to upsize the wire to compensate for voltage drop. NEC recommends keeping voltage drop under 3% for branch circuits. Use our voltage drop calculator to check.
| One-way run | Drop | % of 240V | Verdict |
|---|---|---|---|
| 25 ft | 0.49 V | 0.2% | Within the 3% branch-circuit target |
| 50 ft | 0.98 V | 0.4% | Within the 3% branch-circuit target |
| 75 ft | 1.47 V | 0.6% | Within the 3% branch-circuit target |
| 100 ft | 1.96 V | 0.8% | Within the 3% branch-circuit target |
| 150 ft | 2.94 V | 1.2% | Within the 3% branch-circuit target |
| 200 ft | 3.92 V | 1.6% | Within the 3% branch-circuit target |
Sizing for a 200-amp aluminum feeder depends on the application — see the NEC 310.12 explanation above. A dwelling service or main power feeder uses 4/0 AWG; any other 200-amp feeder needs 250 kcmil (205 A at 75°C).
| Dwelling service / main power feeder | 4/0 AWG aluminum — NEC 310.12 |
| Sub-panel or commercial feeder | 250 kcmil aluminum — NEC Table 310.16 |
| 4/0 aluminum ampacity (75°C) | 180 A |
| 250 kcmil aluminum ampacity (75°C) | 205 A |
| 4/0 aluminum resistance | 0.0753 Ω/1000 ft |