WireSizing
Wire gauge reference & calculator

What Wire Size for 200 Amps?

Copper Wire
4/0 AWG
11.684 mm · 107.2193 mm²
Aluminum Wire
4/0 AWG*
11.684 mm · 107.2193 mm²
*Dwelling services/feeders only — see NEC 310.12 below
Breaker: 200A · Copper per NEC Table 310.16 (75°C insulation) · Aluminum per NEC 310.12

Why 4/0 aluminum works here but not everywhere

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.

Common Uses for 200A Circuits

Residential service entrance, commercial feeders

4/0 AWG Copper — Key Specs

Diameter11.684 mm (0.46")
Area107.2193 mm²
Resistance at 20°C0.1608 Ω/km
Weight960.685 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.

Voltage Drop by Distance — 4/0 AWG Copper at 200A

One-way run Drop % of 240V Verdict
25 ft0.49 V0.2%Within the 3% branch-circuit target
50 ft0.98 V0.4%Within the 3% branch-circuit target
75 ft1.47 V0.6%Within the 3% branch-circuit target
100 ft1.96 V0.8%Within the 3% branch-circuit target
150 ft2.94 V1.2%Within the 3% branch-circuit target
200 ft3.92 V1.6%Within the 3% branch-circuit target
Single-phase, 240V, full 200A load, 0.049 Ω/1000 ft DC resistance (NEC Chapter 9, Table 8) at 75°C terminations. NEC 210.19(A) Informational Note recommends keeping branch-circuit drop at or below 3%, and 5% total across feeder plus branch circuit. Voltage drop is a performance recommendation, not a code requirement — but exceeding it causes dim lights, slow motor starts, and wasted energy.

Aluminum Feeder Specifications

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 feeder4/0 AWG aluminum — NEC 310.12
Sub-panel or commercial feeder250 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 resistance0.0753 Ω/1000 ft

Installing aluminum correctly

  • Modern aluminum building wire must be AA-8000 series alloy (NEC 310.14(A)(1)). The 1960s-era AA-1350 alloy behind aluminum’s bad reputation is no longer permitted for branch circuits.
  • Terminate only on lugs and breakers marked AL/CU or AL9CU. Copper-only terminals are the most common failure point.
  • Apply an antioxidant compound to the stripped conductor before landing it, unless the termination is listed as not requiring it.
  • Torque every connection to the manufacturer’s value with a calibrated torque tool — NEC 110.14(D) makes this mandatory. Loose aluminum terminations are the primary cause of feeder failures.
  • Aluminum runs roughly half the weight and a third to half the cost of copper at feeder sizes, which is why it dominates service entrance and sub-panel feeders.

Related

Wire types and insulation ratings → 200 amp breaker — wire, ground and load → NEC Table 250.122 — ground wire size → 4/0 AWG full specifications → Full AWG chart → Wire size calculator → Ampacity tables →