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When installing or upgrading the electrical system in a home or building, one of the most important components is the circuit breaker. Circuit breakers are designed to protect the wires in a circuit from overheating and potential fire hazard by cutting off power if the current draw exceeds the rated amperage of the breaker. For high power appliances or equipment like electric vehicle chargers, HVAC units, machinery or even full home backup generators, an 80 amp circuit breaker is commonly used. However, the circuit breaker amperage is only one half of the equation. Choosing the proper wire size to pair with an 80 amp breaker is an equally crucial safety consideration.


This article will explore the important factors in selecting the right wire gauge or thickness to safely handle the electricity delivery for an 80 amp circuit, recommendations for common wire size choices, tips for proper installation, common uses for an 80 amp circuit, cost considerations, and safety best practices.

Understanding Ampacity

The term “ampacity” refers to the maximum electric current a wire can safely carry before overheating under defined conditions. Ampacity tables provided by the National Electrical Code (NEC) specify the required wire gauges for different amperage circuit breakers based on various criteria. As a general rule, a standard 80 amp circuit breaker requires a minimum wire size of 6 AWG copper or 4 AWG aluminum. However, this can vary based on other factors, so using the reference tables is important.

Factors that Affect Wire Size

Selecting the proper wire gauge for an 80 amp circuit depends on more than just matching wire size to circuit breaker amperage. Some key factors to consider include:

  • Conductor Material – Copper wire can safely carry more amps than aluminum wire of the same gauge.
  • Ambient Temperature – Wire ampacity decreases as temperature increases.
  • Number of Conductors – More current carrying conductors bundled together have reduced ampacity.
  • Length of Run – Longer wire runs require larger gauges to avoid voltage drop.
  • Single vs. Three Phase – Three phase circuits can use smaller gauges than single phase.

Calculating the Right Wire Size

To determine the proper wire size for an 80 amp circuit, you’ll need to consult ampacity tables like those provided in the NEC. This will account for the various factors mentioned above. Online wire size calculators that reference these tables can simplify the process. You input data like…

– Circuit breaker amp rating (80 amps)
– Conductor metal type (copper or aluminum)
– Ambient temp of the environment
– Number of current carrying conductors
– Length of the wire run

…and the calculator will output the minimum recommended wire gauge to safely support the electrical load.

As an example, for an 80 amp circuit with a 50 foot wire run using 3 current carrying copper conductors in an ambient temperature of 86°F, 6 AWG wire would be required.

NEC Ampacity Table

Recommendations for 80 Amp Circuits

Though calculations should be performed to account for specific conditions, here are some general recommendations for wire gauges typically used with 80 amp breakers:

  • 6 AWG copper wire for runs up to 55 feet
  • 4 AWG copper wire for runs up to 85 feet
  • 2 AWG copper wire for runs up to 140 feet
  • 4 AWG aluminum wire for runs up to 70 feet
  • 2 AWG aluminum wire for runs up to 115 feet

These recommendations assume 3 current carrying conductors at an ambient temperature of 86°F. Lengths can vary based on environment. When in doubt, consult the code tables or wire size calculator.

Aluminum vs. Copper Wire

Both copper and aluminum wire can be used with 80 amp circuits, but there are a few key differences:

Copper has higher ampacity so can use smaller gauges. It also has better conductivity and is less prone to oxidation. But copper costs more than aluminum.

Aluminum is lighter in weight than copper of the same gauge. And it costs significantly less than copper. But aluminum has lower ampacity so requires larger wire sizes. It’s also more prone to oxidation and expansion/contraction with temperature changes.

Proper connectors and terminations must be used with aluminum wire to prevent oxidation and loose connections from temperature changes. Overall, copper is generally preferred when budget allows.

Types of Wire

There are a few different types of wiring that can be used with 80 amp circuits:

Nonmetallic (NM) cable with copper conductors is common for residential branch circuits. An 8 AWG 3 conductor NM cable would be well suited for an 80 amp home circuit.

UF cable is designed for direct underground burial and wet locations. 4 AWG aluminum UF cable works for 80 amp underground feeds.

THHN and THWN are single insulated wires run through conduit. These are common in commercial and industrial applications. 6 AWG THHN copper wire is suitable for 80 amps.

XHHW is dual-rated wire that can be used for both wet and dry locations. Often used to wire hot tubs or other outdoor circuits using an 80 amp GFCI breaker.

Proper Installation

When installing larger gauge wires for an 80 amp circuit, proper techniques are important:

– Use the right size breakers, connectors, terminals, and conduits rated for the wire size. Underrated components can overheat.

– Maintain proper bend radius for the wire when running through conduits to avoid damage.

– Use wire pulling lubricant when pulling wires through conduit to reduce friction and strain.

– Use cable ties, staples, or other fasteners at regular intervals for neat and secure installation.

– Carefully strip insulation from ends using proper wire strippers. Avoid nicking or damaging the conductor.

– Make tight, clean connections to terminals and fasten lugs securely. Poor connections can lead to arcing/overheating.

– Carefully label both ends of each wire for easy identification.

Common Uses for 80 Amp Circuits

Some typical applications for 80 amp circuit breakers and associated wiring:

Electric vehicle chargers – Most Level 2 EVSE stations require 40-100 amp circuits. An 80 amp circuit supports charging most EVs at full speed.

Air conditioners – Central AC units often need a 60-80 amp dual pole breaker and appropriately sized wiring.

Electric dryers – Many 240V residential dryers require 30-80 amp circuits. An 80 amp breaker allows for larger capacity dryers.

Electric ranges & ovens – Ranges with multiple ovens or cooktops can require 40-80 dedicated amp circuits.

Hot tubs & spas – An 80 amp GFCI breaker with sufficient wire allows safe operation of pumps and heaters.

Standard subpanels – An 80 amp feed supplies up to 100 amp subpanel for optional standby loads like well pumps or shops.

Backup home generators – Whole house standby generators often require 60-100 amp transfer switches.

Cost Considerations

Wire costs increase as the gauge size goes up, so using the smallest wire size necessary for the amperage capacity helps control costs. Here are some rough estimates for materials to wire a typical 80 amp circuit run:

– 6 AWG THHN copper wire – Approximately $3-5 per foot
– 6 AWG NM copper cable – Approximately $4-7 per foot
– 4 AWG THHN aluminum wire – Approximately $2-3 per foot
– 80 amp breaker – $20-60 depending on type/brand

So for a 50 foot circuit length, total materials would be $150-350 for copper or $100-250 for aluminum. Copper wire costs more upfront but can save on long term energy costs compared to undersized aluminum. Proper installation is also key to realizing the benefits of adequately sized wires.

Safety Tips

When working with 80 amp circuits, it’s extremely important to follow proper safety protocols to avoid shock or electrocution hazards:

– Use PPE like insulated gloves, eye protection, sturdy shoes, and flame resistant clothing.

– De-energize circuits at the main breaker panel before working on them. Verify wires are de-energized with a multimeter or tester.

– Ensure electrical panels and junction boxes remain securely closed and inaccessible to others while circuits are live.

– Clearly label all circuit breakers and disconnects. 80 amp circuits can generate lethal currents and arcs.

– Follow all codes and standards like the NEC, especially regarding required wire sizes, overcurrent protection, and GFCI protection near water sources.

– Be vigilant of aluminum wire terminations overheating. Use the right connectors rated for large aluminum wire.


Installing the proper wire size to pair with an 80 amp circuit breaker is critical for safety and optimal electrical system performance. Make sure to account for all relevant factors like wire material, length of run, number of conductors, and ambient temperature when determining the correct wire gauge. Following code requirements, using quality materials, making solid terminations, and adhering to safe work practices will ensure a reliable 80 amp circuit that provides protection from overloads and faults. Proper planning, careful execution, and regular maintenance gives you peace of mind that your 80 amp circuit wiring will operate safely for years to come.

Published On: 2023年9月6日Categories: ,