80 Amp Wire Size at 40 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 80 A load over a 40 ft (12.2 m) one-way run.
Copper Wire (≤3% Drop)250 kcmil126.7 mm² · Drop: 2.75%
Aluminum Wire (≤3% Drop)400 kcmilDrop: 0.34V (2.83%)
Voltage at Load End11.7 VLoss: 0.33 V (26.4 W)
Power & Breaker (125%)0.96 kW100A Breaker Recommended
All AWG & kcmil Wire Gauges for 80 Amps at 40 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 | 20.07 V (167.25%) | 0.0 V | 33.11 V (275.88%) | 1605.6 W | Drop/Amp High |
| 12 AWG | 3.31 mm² | 20 A | 12.61 V (105.1%) | 0.0 V | 20.8 V (173.36%) | 1009.0 W | Drop/Amp High |
| 10 AWG | 5.26 mm² | 30 A | 7.94 V (66.14%) | 4.1 V | 13.09 V (109.09%) | 634.9 W | Drop/Amp High |
| 8 AWG | 8.37 mm² | 50 A | 4.99 V (41.56%) | 7.0 V | 8.23 V (68.56%) | 399.0 W | Drop/Amp High |
| 6 AWG | 13.3 mm² | 65 A | 3.14 V (26.16%) | 8.9 V | 5.18 V (43.15%) | 251.1 W | Drop/Amp High |
| 4 AWG | 21.15 mm² | 85 A | 1.97 V (16.45%) | 10.0 V | 3.26 V (27.13%) | 157.9 W | Drop/Amp High |
| 3 AWG | 26.67 mm² | 100 A | 1.57 V (13.04%) | 10.4 V | 2.58 V (21.52%) | 125.2 W | Drop/Amp High |
| 2 AWG | 33.62 mm² | 115 A | 1.24 V (10.35%) | 10.8 V | 2.05 V (17.07%) | 99.3 W | Drop/Amp High |
| 1 AWG | 42.41 mm² | 130 A | 0.98 V (8.2%) | 11.0 V | 1.62 V (13.53%) | 78.7 W | Drop/Amp High |
| 1/0 AWG | 53.49 mm² | 150 A | 0.78 V (6.5%) | 11.2 V | 1.29 V (10.73%) | 62.4 W | Drop/Amp High |
| 2/0 AWG | 67.43 mm² | 175 A | 0.62 V (5.16%) | 11.4 V | 1.02 V (8.51%) | 49.5 W | Drop/Amp High |
| 3/0 AWG | 85.01 mm² | 200 A | 0.49 V (4.09%) | 11.5 V | 0.81 V (6.75%) | 39.3 W | ~ ≤5% |
| 4/0 AWG | 107.2 mm² | 230 A | 0.39 V (3.25%) | 11.6 V | 0.64 V (5.35%) | 31.2 W | ~ ≤5% |
| 250 kcmil | 126.7 mm² | 255 A | 0.33 V (2.75%) | 11.7 V | 0.54 V (4.53%) | 26.4 W | ✓ PASS (≤3%) |
| 300 kcmil | 152.0 mm² | 285 A | 0.27 V (2.29%) | 11.7 V | 0.45 V (3.78%) | 22.0 W | ✓ PASS (≤3%) |
| 350 kcmil | 177.3 mm² | 310 A | 0.24 V (1.96%) | 11.8 V | 0.39 V (3.24%) | 18.8 W | ✓ PASS (≤3%) |
| 400 kcmil | 202.7 mm² | 335 A | 0.21 V (1.72%) | 11.8 V | 0.34 V (2.83%) | 16.5 W | ✓ PASS (≤3%) |
| 500 kcmil | 253.4 mm² | 380 A | 0.16 V (1.37%) | 11.8 V | 0.27 V (2.26%) | 13.2 W | ✓ PASS (≤3%) |
| 600 kcmil | 304.0 mm² | 420 A | 0.14 V (1.14%) | 11.9 V | 0.23 V (1.89%) | 11.0 W | ✓ PASS (≤3%) |
| 750 kcmil | 380.0 mm² | 475 A | 0.11 V (0.92%) | 11.9 V | 0.18 V (1.51%) | 8.8 W | ✓ PASS (≤3%) |
| 1000 kcmil | 506.7 mm² | 545 A | 0.08 V (0.69%) | 11.9 V | 0.14 V (1.13%) | 6.6 W | ✓ PASS (≤3%) |
Frequently Asked Engineering Questions
What size copper wire do I need for 80 amps at 40 feet (12V)?
To stay within the NEC recommended 3% maximum voltage drop for a 80A load over 40 feet one-way at 12V (DC), you need 250 kcmil copper wire. This produces a voltage drop of 0.33V (2.75%) and delivers 11.7V at the load.
What size aluminum wire is required for 80 amps at 40 feet?
Using aluminum conductors (75°C rating), you should use 400 kcmil to maintain voltage drop at 0.34V (2.83%).
What breaker size is needed for a 80A continuous load?
Under NEC 210.20(A), continuous loads require a circuit breaker rated at 125% of the continuous current (80A × 1.25 = 100.0A), which corresponds to a standard 100A circuit breaker.
Compare Other Distances & Amperages
80 Amp Wire Size by Distance (12V)
80A at 20 ft (12V)80A at 30 ft (12V)80A at 50 ft (12V)80A at 60 ft (12V)80A at 75 ft (12V)80A at 80 ft (12V)80A at 100 ft (12V)80A at 120 ft (12V)80A at 125 ft (12V)80A at 150 ft (12V)80A at 175 ft (12V)