![]() Managing Larger Wire Bend Radius RequirementsĪs aluminum wire gauge increases, so does the minimum bend radius to avoid damage during handling and pull-through. Properly supporting thicker aluminum wire during installation is advised. The tradeoff is #1 is less flexible, with a thicker insulation jacket. But for only slightly higher cost, oversizing wiring enables lower voltage drop and added future capacity.įor 100 amps, #1 or 1/0 AWG aluminum runs cooler with even less voltage loss over long cable distances. ![]() The most popular choice is the code minimum #2 AWG aluminum, costing around $2.50 per foot. These capacity, temperature, and insulation qualifications make #2 AWG aluminum wire well-suited for 100-amp service. The thick THHN insulation is designed for wet or dry installation. In addition to checking ampacity, #2 AWG aluminum wire meets NEC standards for high temperature operations up to 90degC. Confirming Temperature and Insulation Ratings This leeway prevents nuisance tripping while protecting the integrity of the wire insulation. The ampacity rating of #2 aluminum wire is 115 amps, providing a 15% buffer above a 100-amp circuit breaker. For 100 amps on a 120/240-volt system, NEC table 310.15(B)(16) specifies #2 AWG wiring as the minimum size, for both copper and aluminum conductors. National Electrical Code (NEC) outlines minimum wire sizes to safely supply circuit ampacity without dangerous overheating. Recommended Aluminum Wire Size for a 100-Amp Breaker Plus added margin for unanticipated loads or expansions, we can determine that 100-amp service with #2 AWG aluminum wire should suffice. Summing these, we would need around 190 amps of capacity. Miscellaneous outlets and lighting: 35+ amps.home may need to account for appliances like: Referencing nameplate ratings, tally up the minimum circuit amps needed.įor example, a typical 2100 sq. Consider lights, outlets, major appliances, and any hardwired equipment. To choose an appropriately sized aluminum wire gauge for 100 amps, we must first sum the expected electrical loads. Calculating Expected Loads for a 100-Amp Circuit Following these best practices for aluminum connections prevents safety issues down the road. Proper torque levels ensure solid contact without damaging soft aluminum metal. Apply antioxidant paste to connections to forestall oxidation. Twisting stranded aluminum wires helps make solid contact inside connectors. Dedicated aluminum electrical accessories prevent this hazardous breakdown over years of use. Mixing metals can cause galvanic corrosion. Special Connections Needed for Aluminum WiresĪluminum wiring must be paired with compatible lugs, terminals, switches, and outlets designed for aluminum. Proper connections and anti-oxidation measures are essential. However, aluminum wiring has special installation and maintenance requirements compared to copper. However, aluminum has a lower melting point and higher resistance than copper.įor 100-amp applications, aluminum is an excellent choice to save on materials cost. Comparing properties, aluminum conducts electricity nearly as well as copper, while being lighter in weight and lower in expense. The most cost-effective residential wiring options are copper and aluminum. Let’s uncover the secrets to ideal 100-amp aluminum wire sizing. You’ll learn the signs of overloaded wires and solutions for correcting undersized aluminum circuits. We’ll compare aluminum and copper conductors, calculate expected loads, explore recommended wire sizes per code, review common options, detail proper installation methods, and outline inspection and maintenance needs.
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