What Gauge Wire for 100 Amps?

Selecting the correct wire gauge is critical for both safety and system efficiency. Undersized wire creates resistance, which generates heat and wastes energy. In mild cases, this results in voltage drop that can prevent equipment from operating correctly or damage sensitive electronics. In severe cases, the heat buildup can melt insulation, causing short circuits or fires. Electrical codes specify minimum wire sizes for good reason - they represent decades of experience with real-world failures. When working with DC systems common in solar and battery setups, wire sizing becomes even more critical because the lower voltages mean higher currents for the same power level, amplifying the consequences of undersized wiring.

The relationship between amperage, distance, and voltage drop determines your wire gauge requirements. As current flows through wire, some voltage is lost to resistance - this is called voltage drop. The longer the wire run and the higher the current, the greater the voltage drop. Most electrical systems aim to keep voltage drop below 3% for efficiency and equipment compatibility, though some applications tolerate up to 5%. The critical insight is that wire runs are measured as round-trip distance: current must travel to the load and return to the source. A device mounted 25 feet from your battery requires 50 feet of wire path, effectively doubling the resistance compared to what you might initially calculate.

DC and AC circuits have fundamentally different wire sizing requirements, primarily due to voltage differences. A 12V DC system carrying 100 watts draws about 8.3 amps, while a 120V AC system carrying the same 100 watts draws less than 1 amp. Higher current means larger wire is needed to keep voltage drop acceptable. This is why DC systems, especially 12V configurations, often require surprisingly thick wire for seemingly modest loads. A 12V circuit powering a 500-watt inverter might need 4 AWG wire for a 15-foot run, while an equivalent 120V AC circuit could use 14 AWG wire. When designing solar and battery systems, consider using 24V or 48V batteries to reduce current and wire costs, especially for larger installations or longer wire runs.

Building in a safety margin when selecting wire gauge protects against future changes and real-world variations. Professional electricians typically size up at least one gauge from the calculated minimum, and often more for long runs or critical circuits. This margin accounts for several factors: wire terminals and connections add resistance not included in basic calculations, temperature affects wire resistance (hot wire has higher resistance), and your loads may increase over time as you add equipment. For battery and solar installations, where reliability during emergencies may be essential, the modest additional cost of heavier wire provides meaningful protection against problems that are difficult to diagnose and expensive to fix after installation.