25 Amp Wire Size at 500 Feet (12V DC (Solar / Automotive / Marine))
Complete conductor sizing, Ohm's law voltage drop, $I^2R$ line power loss, and circuit breaker specification for a 25 A load over a 500 ft (152.4 m) one-way run.
Copper Wire (≤3% Drop)1000 kcmil506.7 mm² · Drop: 2.68%
Aluminum Wire (≤3% Drop)1000 kcmilDrop: 0.53V (4.42%)
Voltage at Load End11.7 VLoss: 0.32 V (8.0 W)
Power & Breaker (125%)0.3 kW32A Breaker Recommended
All AWG & kcmil Wire Gauges for 25 Amps at 500 Feet (12V)
| 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 | 78.4 V (653.32%) | 0.0 V | 129.32 V (1077.67%) | 1960.0 W | Drop/Amp High |
| 12 AWG | 3.31 mm² | 20 A | 49.27 V (410.54%) | 0.0 V | 81.26 V (677.21%) | 1231.6 W | Drop/Amp High |
| 10 AWG | 5.26 mm² | 30 A | 31.0 V (258.35%) | 0.0 V | 51.14 V (426.15%) | 775.0 W | Drop/Amp High |
| 8 AWG | 8.37 mm² | 50 A | 19.48 V (162.35%) | 0.0 V | 32.14 V (267.81%) | 487.1 W | Drop/Amp High |
| 6 AWG | 13.3 mm² | 65 A | 12.26 V (102.17%) | 0.0 V | 20.22 V (168.54%) | 306.5 W | Drop/Amp High |
| 4 AWG | 21.15 mm² | 85 A | 7.71 V (64.25%) | 4.3 V | 12.72 V (105.98%) | 192.8 W | Drop/Amp High |
| 3 AWG | 26.67 mm² | 100 A | 6.11 V (50.95%) | 5.9 V | 10.09 V (84.05%) | 152.9 W | Drop/Amp High |
| 2 AWG | 33.62 mm² | 115 A | 4.85 V (40.42%) | 7.1 V | 8.0 V (66.67%) | 121.3 W | Drop/Amp High |
| 1 AWG | 42.41 mm² | 130 A | 3.85 V (32.04%) | 8.2 V | 6.34 V (52.85%) | 96.1 W | Drop/Amp High |
| 1/0 AWG | 53.49 mm² | 150 A | 3.05 V (25.4%) | 9.0 V | 5.03 V (41.91%) | 76.2 W | Drop/Amp High |
| 2/0 AWG | 67.43 mm² | 175 A | 2.42 V (20.15%) | 9.6 V | 3.99 V (33.24%) | 60.5 W | Drop/Amp High |
| 3/0 AWG | 85.01 mm² | 200 A | 1.92 V (15.99%) | 10.1 V | 3.16 V (26.37%) | 48.0 W | Drop/Amp High |
| 4/0 AWG | 107.2 mm² | 230 A | 1.52 V (12.68%) | 10.5 V | 2.51 V (20.91%) | 38.0 W | Drop/Amp High |
| 250 kcmil | 126.7 mm² | 255 A | 1.29 V (10.73%) | 10.7 V | 2.12 V (17.69%) | 32.2 W | Drop/Amp High |
| 300 kcmil | 152.0 mm² | 285 A | 1.07 V (8.94%) | 10.9 V | 1.77 V (14.75%) | 26.8 W | Drop/Amp High |
| 350 kcmil | 177.3 mm² | 310 A | 0.92 V (7.66%) | 11.1 V | 1.52 V (12.64%) | 23.0 W | Drop/Amp High |
| 400 kcmil | 202.7 mm² | 335 A | 0.8 V (6.7%) | 11.2 V | 1.33 V (11.06%) | 20.1 W | Drop/Amp High |
| 500 kcmil | 253.4 mm² | 380 A | 0.64 V (5.36%) | 11.4 V | 1.06 V (8.85%) | 16.1 W | Drop/Amp High |
| 600 kcmil | 304.0 mm² | 420 A | 0.54 V (4.47%) | 11.5 V | 0.88 V (7.37%) | 13.4 W | ~ ≤5% |
| 750 kcmil | 380.0 mm² | 475 A | 0.43 V (3.58%) | 11.6 V | 0.71 V (5.9%) | 10.7 W | ~ ≤5% |
| 1000 kcmil | 506.7 mm² | 545 A | 0.32 V (2.68%) | 11.7 V | 0.53 V (4.42%) | 8.0 W | ✓ PASS (≤3%) |
Frequently Asked Engineering Questions
What size copper wire do I need for 25 amps at 500 feet (12V)?
To stay within the NEC recommended 3% maximum voltage drop for a 25A load over 500 feet one-way at 12V (DC), you need 1000 kcmil copper wire. This produces a voltage drop of 0.32V (2.68%) and delivers 11.7V at the load.
What size aluminum wire is required for 25 amps at 500 feet?
Using aluminum conductors (75°C rating), you should use 1000 kcmil to maintain voltage drop at 0.53V (4.42%).
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 (12V)
25A at 20 ft (12V)25A at 30 ft (12V)25A at 40 ft (12V)25A at 50 ft (12V)25A at 60 ft (12V)25A at 75 ft (12V)25A at 80 ft (12V)25A at 100 ft (12V)25A at 120 ft (12V)25A at 125 ft (12V)25A at 150 ft (12V)25A at 175 ft (12V)