25 Amp Wire Size at 40 Feet (240V Split-Phase (US Dryer / EV / Subpanel))
Complete conductor sizing, Ohm's law voltage drop, $I^2R$ line power loss, and circuit breaker specification for a 25 A load over a 40 ft (12.2 m) one-way run.
Copper Wire (≤3% Drop)10 AWG5.26 mm² · Drop: 1.03%
Aluminum Wire (≤3% Drop)10 AWGDrop: 4.09V (1.7%)
Voltage at Load End237.5 VLoss: 2.48 V (62.0 W)
Power & Breaker (125%)6.0 kW32A Breaker Recommended
All AWG & kcmil Wire Gauges for 25 Amps at 40 Feet (240V)
| Wire Gauge | Metric Area | NEC 75°C Cu Ampacity | Copper Voltage Drop | Load Voltage | Aluminum Drop | Line Loss ($I^2R$) | NEC Status |
|---|---|---|---|---|---|---|---|
| 14 AWG | 2.08 mm² | 15 A | 6.27 V (2.61%) | 233.7 V | 10.35 V (4.31%) | 156.8 W | Drop/Amp High |
| 12 AWG | 3.31 mm² | 20 A | 3.94 V (1.64%) | 236.1 V | 6.5 V (2.71%) | 98.5 W | Drop/Amp High |
| 10 AWG | 5.26 mm² | 30 A | 2.48 V (1.03%) | 237.5 V | 4.09 V (1.7%) | 62.0 W | ✓ PASS (≤3%) |
| 8 AWG | 8.37 mm² | 50 A | 1.56 V (0.65%) | 238.4 V | 2.57 V (1.07%) | 39.0 W | ✓ PASS (≤3%) |
| 6 AWG | 13.3 mm² | 65 A | 0.98 V (0.41%) | 239.0 V | 1.62 V (0.67%) | 24.5 W | ✓ PASS (≤3%) |
| 4 AWG | 21.15 mm² | 85 A | 0.62 V (0.26%) | 239.4 V | 1.02 V (0.42%) | 15.4 W | ✓ PASS (≤3%) |
| 3 AWG | 26.67 mm² | 100 A | 0.49 V (0.2%) | 239.5 V | 0.81 V (0.34%) | 12.2 W | ✓ PASS (≤3%) |
| 2 AWG | 33.62 mm² | 115 A | 0.39 V (0.16%) | 239.6 V | 0.64 V (0.27%) | 9.7 W | ✓ PASS (≤3%) |
| 1 AWG | 42.41 mm² | 130 A | 0.31 V (0.13%) | 239.7 V | 0.51 V (0.21%) | 7.7 W | ✓ PASS (≤3%) |
| 1/0 AWG | 53.49 mm² | 150 A | 0.24 V (0.1%) | 239.8 V | 0.4 V (0.17%) | 6.1 W | ✓ PASS (≤3%) |
| 2/0 AWG | 67.43 mm² | 175 A | 0.19 V (0.08%) | 239.8 V | 0.32 V (0.13%) | 4.8 W | ✓ PASS (≤3%) |
| 3/0 AWG | 85.01 mm² | 200 A | 0.15 V (0.06%) | 239.8 V | 0.25 V (0.11%) | 3.8 W | ✓ PASS (≤3%) |
| 4/0 AWG | 107.2 mm² | 230 A | 0.12 V (0.05%) | 239.9 V | 0.2 V (0.08%) | 3.0 W | ✓ PASS (≤3%) |
| 250 kcmil | 126.7 mm² | 255 A | 0.1 V (0.04%) | 239.9 V | 0.17 V (0.07%) | 2.6 W | ✓ PASS (≤3%) |
| 300 kcmil | 152.0 mm² | 285 A | 0.09 V (0.04%) | 239.9 V | 0.14 V (0.06%) | 2.1 W | ✓ PASS (≤3%) |
| 350 kcmil | 177.3 mm² | 310 A | 0.07 V (0.03%) | 239.9 V | 0.12 V (0.05%) | 1.8 W | ✓ PASS (≤3%) |
| 400 kcmil | 202.7 mm² | 335 A | 0.06 V (0.03%) | 239.9 V | 0.11 V (0.04%) | 1.6 W | ✓ PASS (≤3%) |
| 500 kcmil | 253.4 mm² | 380 A | 0.05 V (0.02%) | 239.9 V | 0.08 V (0.04%) | 1.3 W | ✓ PASS (≤3%) |
| 600 kcmil | 304.0 mm² | 420 A | 0.04 V (0.02%) | 240.0 V | 0.07 V (0.03%) | 1.1 W | ✓ PASS (≤3%) |
| 750 kcmil | 380.0 mm² | 475 A | 0.03 V (0.01%) | 240.0 V | 0.06 V (0.02%) | 0.9 W | ✓ PASS (≤3%) |
| 1000 kcmil | 506.7 mm² | 545 A | 0.03 V (0.01%) | 240.0 V | 0.04 V (0.02%) | 0.6 W | ✓ PASS (≤3%) |
Frequently Asked Engineering Questions
What size copper wire do I need for 25 amps at 40 feet (240V)?
To stay within the NEC recommended 3% maximum voltage drop for a 25A load over 40 feet one-way at 240V (1-Phase), you need 10 AWG copper wire. This produces a voltage drop of 2.48V (1.03%) and delivers 237.5V at the load.
What size aluminum wire is required for 25 amps at 40 feet?
Using aluminum conductors (75°C rating), you should use 10 AWG to maintain voltage drop at 4.09V (1.7%).
What breaker size is needed for a 25A continuous load?
Under NEC 210.20(A), continuous loads require a circuit breaker rated at 125% of the continuous current (25A × 1.25 = 31.2A), which corresponds to a standard 32A circuit breaker.
Compare Other Distances & Amperages
25 Amp Wire Size by Distance (240V)
25A at 20 ft (240V)25A at 30 ft (240V)25A at 50 ft (240V)25A at 60 ft (240V)25A at 75 ft (240V)25A at 80 ft (240V)25A at 100 ft (240V)25A at 120 ft (240V)25A at 125 ft (240V)25A at 150 ft (240V)25A at 175 ft (240V)