90 Amp Wire Size at 80 Feet (480V Three-Phase (US Heavy Industrial))
Complete conductor sizing, Ohm's law voltage drop, $I^2R$ line power loss, and circuit breaker specification for a 90 A load over a 80 ft (24.4 m) one-way run.
Copper Wire (≤3% Drop)3 AWG26.67 mm² · Drop: 0.64%
Aluminum Wire (≤3% Drop)2 AWGDrop: 3.99V (0.83%)
Voltage at Load End477.0 VLoss: 3.05 V (475.4 W)
Power & Breaker (125%)74.82 kW125A Breaker Recommended
All AWG & kcmil Wire Gauges for 90 Amps at 80 Feet (480V)
| 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 | 39.11 V (8.15%) | 440.9 V | 64.51 V (13.44%) | 6096.2 W | Drop/Amp High |
| 12 AWG | 3.31 mm² | 20 A | 24.58 V (5.12%) | 455.4 V | 40.54 V (8.45%) | 3830.9 W | Drop/Amp High |
| 10 AWG | 5.26 mm² | 30 A | 15.46 V (3.22%) | 464.5 V | 25.51 V (5.31%) | 2410.7 W | Drop/Amp High |
| 8 AWG | 8.37 mm² | 50 A | 9.72 V (2.02%) | 470.3 V | 16.03 V (3.34%) | 1515.0 W | Drop/Amp High |
| 6 AWG | 13.3 mm² | 65 A | 6.12 V (1.27%) | 473.9 V | 10.09 V (2.1%) | 953.4 W | Drop/Amp High |
| 4 AWG | 21.15 mm² | 85 A | 3.85 V (0.8%) | 476.2 V | 6.34 V (1.32%) | 599.5 W | Drop/Amp High |
| 3 AWG | 26.67 mm² | 100 A | 3.05 V (0.64%) | 477.0 V | 5.03 V (1.05%) | 475.4 W | ✓ PASS (≤3%) |
| 2 AWG | 33.62 mm² | 115 A | 2.42 V (0.5%) | 477.6 V | 3.99 V (0.83%) | 377.2 W | ✓ PASS (≤3%) |
| 1 AWG | 42.41 mm² | 130 A | 1.92 V (0.4%) | 478.1 V | 3.16 V (0.66%) | 299.0 W | ✓ PASS (≤3%) |
| 1/0 AWG | 53.49 mm² | 150 A | 1.52 V (0.32%) | 478.5 V | 2.51 V (0.52%) | 237.1 W | ✓ PASS (≤3%) |
| 2/0 AWG | 67.43 mm² | 175 A | 1.21 V (0.25%) | 478.8 V | 1.99 V (0.41%) | 188.0 W | ✓ PASS (≤3%) |
| 3/0 AWG | 85.01 mm² | 200 A | 0.96 V (0.2%) | 479.0 V | 1.58 V (0.33%) | 149.2 W | ✓ PASS (≤3%) |
| 4/0 AWG | 107.2 mm² | 230 A | 0.76 V (0.16%) | 479.2 V | 1.25 V (0.26%) | 118.3 W | ✓ PASS (≤3%) |
| 250 kcmil | 126.7 mm² | 255 A | 0.64 V (0.13%) | 479.4 V | 1.06 V (0.22%) | 100.1 W | ✓ PASS (≤3%) |
| 300 kcmil | 152.0 mm² | 285 A | 0.54 V (0.11%) | 479.5 V | 0.88 V (0.18%) | 83.4 W | ✓ PASS (≤3%) |
| 350 kcmil | 177.3 mm² | 310 A | 0.46 V (0.1%) | 479.5 V | 0.76 V (0.16%) | 71.5 W | ✓ PASS (≤3%) |
| 400 kcmil | 202.7 mm² | 335 A | 0.4 V (0.08%) | 479.6 V | 0.66 V (0.14%) | 62.6 W | ✓ PASS (≤3%) |
| 500 kcmil | 253.4 mm² | 380 A | 0.32 V (0.07%) | 479.7 V | 0.53 V (0.11%) | 50.0 W | ✓ PASS (≤3%) |
| 600 kcmil | 304.0 mm² | 420 A | 0.27 V (0.06%) | 479.7 V | 0.44 V (0.09%) | 41.7 W | ✓ PASS (≤3%) |
| 750 kcmil | 380.0 mm² | 475 A | 0.21 V (0.04%) | 479.8 V | 0.35 V (0.07%) | 33.4 W | ✓ PASS (≤3%) |
| 1000 kcmil | 506.7 mm² | 545 A | 0.16 V (0.03%) | 479.8 V | 0.26 V (0.06%) | 25.0 W | ✓ PASS (≤3%) |
Frequently Asked Engineering Questions
What size copper wire do I need for 90 amps at 80 feet (480V)?
To stay within the NEC recommended 3% maximum voltage drop for a 90A load over 80 feet one-way at 480V (3-Phase), you need 3 AWG copper wire. This produces a voltage drop of 3.05V (0.64%) and delivers 477.0V at the load.
What size aluminum wire is required for 90 amps at 80 feet?
Using aluminum conductors (75°C rating), you should use 2 AWG to maintain voltage drop at 3.99V (0.83%).
What breaker size is needed for a 90A continuous load?
Under NEC 210.20(A), continuous loads require a circuit breaker rated at 125% of the continuous current (90A × 1.25 = 112.5A), which corresponds to a standard 125A circuit breaker.
Compare Other Distances & Amperages
90 Amp Wire Size by Distance (480V)
90A at 20 ft (480V)90A at 30 ft (480V)90A at 40 ft (480V)90A at 50 ft (480V)90A at 60 ft (480V)90A at 75 ft (480V)90A at 100 ft (480V)90A at 120 ft (480V)90A at 125 ft (480V)90A at 150 ft (480V)90A at 175 ft (480V)