500 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 500 A load over a 40 ft (12.2 m) one-way run.
Copper Wire (≤3% Drop)1000 kcmil506.7 mm² · Drop: 0.21%
Aluminum Wire (≤3% Drop)1000 kcmilDrop: 0.85V (0.35%)
Voltage at Load End239.5 VLoss: 0.51 V (257.5 W)
Power & Breaker (125%)120.0 kW700A Breaker Recommended
All AWG & kcmil Wire Gauges for 500 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 | 125.44 V (52.27%) | 114.6 V | 206.91 V (86.21%) | 62718.5 W | Drop/Amp High |
| 12 AWG | 3.31 mm² | 20 A | 78.82 V (32.84%) | 161.2 V | 130.02 V (54.18%) | 39412.2 W | Drop/Amp High |
| 10 AWG | 5.26 mm² | 30 A | 49.6 V (20.67%) | 190.4 V | 81.82 V (34.09%) | 24801.2 W | Drop/Amp High |
| 8 AWG | 8.37 mm² | 50 A | 31.17 V (12.99%) | 208.8 V | 51.42 V (21.42%) | 15585.9 W | Drop/Amp High |
| 6 AWG | 13.3 mm² | 65 A | 19.62 V (8.17%) | 220.4 V | 32.36 V (13.48%) | 9808.6 W | Drop/Amp High |
| 4 AWG | 21.15 mm² | 85 A | 12.34 V (5.14%) | 227.7 V | 20.35 V (8.48%) | 6168.1 W | Drop/Amp High |
| 3 AWG | 26.67 mm² | 100 A | 9.78 V (4.08%) | 230.2 V | 16.14 V (6.72%) | 4891.4 W | Drop/Amp High |
| 2 AWG | 33.62 mm² | 115 A | 7.76 V (3.23%) | 232.2 V | 12.8 V (5.33%) | 3880.3 W | Drop/Amp High |
| 1 AWG | 42.41 mm² | 130 A | 6.15 V (2.56%) | 233.8 V | 10.15 V (4.23%) | 3076.0 W | Drop/Amp High |
| 1/0 AWG | 53.49 mm² | 150 A | 4.88 V (2.03%) | 235.1 V | 8.05 V (3.35%) | 2438.9 W | Drop/Amp High |
| 2/0 AWG | 67.43 mm² | 175 A | 3.87 V (1.61%) | 236.1 V | 6.38 V (2.66%) | 1934.7 W | Drop/Amp High |
| 3/0 AWG | 85.01 mm² | 200 A | 3.07 V (1.28%) | 236.9 V | 5.06 V (2.11%) | 1534.6 W | Drop/Amp High |
| 4/0 AWG | 107.2 mm² | 230 A | 2.43 V (1.01%) | 237.6 V | 4.01 V (1.67%) | 1216.9 W | Drop/Amp High |
| 250 kcmil | 126.7 mm² | 255 A | 2.06 V (0.86%) | 237.9 V | 3.4 V (1.42%) | 1029.6 W | Drop/Amp High |
| 300 kcmil | 152.0 mm² | 285 A | 1.72 V (0.72%) | 238.3 V | 2.83 V (1.18%) | 858.3 W | Drop/Amp High |
| 350 kcmil | 177.3 mm² | 310 A | 1.47 V (0.61%) | 238.5 V | 2.43 V (1.01%) | 735.8 W | Drop/Amp High |
| 400 kcmil | 202.7 mm² | 335 A | 1.29 V (0.54%) | 238.7 V | 2.12 V (0.88%) | 643.6 W | Drop/Amp High |
| 500 kcmil | 253.4 mm² | 380 A | 1.03 V (0.43%) | 239.0 V | 1.7 V (0.71%) | 514.8 W | Drop/Amp High |
| 600 kcmil | 304.0 mm² | 420 A | 0.86 V (0.36%) | 239.1 V | 1.42 V (0.59%) | 429.1 W | Drop/Amp High |
| 750 kcmil | 380.0 mm² | 475 A | 0.69 V (0.29%) | 239.3 V | 1.13 V (0.47%) | 343.3 W | Drop/Amp High |
| 1000 kcmil | 506.7 mm² | 545 A | 0.51 V (0.21%) | 239.5 V | 0.85 V (0.35%) | 257.5 W | ✓ PASS (≤3%) |
Frequently Asked Engineering Questions
What size copper wire do I need for 500 amps at 40 feet (240V)?
To stay within the NEC recommended 3% maximum voltage drop for a 500A load over 40 feet one-way at 240V (1-Phase), you need 1000 kcmil copper wire. This produces a voltage drop of 0.51V (0.21%) and delivers 239.5V at the load.
What size aluminum wire is required for 500 amps at 40 feet?
Using aluminum conductors (75°C rating), you should use 1000 kcmil to maintain voltage drop at 0.85V (0.35%).
What breaker size is needed for a 500A continuous load?
Under NEC 210.20(A), continuous loads require a circuit breaker rated at 125% of the continuous current (500A × 1.25 = 625.0A), which corresponds to a standard 700A circuit breaker.
Compare Other Distances & Amperages
500 Amp Wire Size by Distance (240V)
500A at 20 ft (240V)500A at 30 ft (240V)500A at 50 ft (240V)500A at 60 ft (240V)500A at 75 ft (240V)500A at 80 ft (240V)500A at 100 ft (240V)500A at 120 ft (240V)500A at 125 ft (240V)500A at 150 ft (240V)500A at 175 ft (240V)