What Size Wire for 80 Amp Breaker | How to Choose Perfect Wire Size

A 2-gauge wire is required for 80-amp service. After 1-gauge, the next size is 2/0, followed by 3/0. It should be noted that if the material is copper, you can only use 2 or 3 gauge wire. Aluminum is less conductive than copper. 1AWG aluminum wire is required to configure an 80-amp service.

What Size Wire for 80 Amp Breaker

A circuit breaker is a type of electrical switch that protects an electrical circuit from damage caused by overcurrent/overload or short-circuit. Its primary function is to stop current flow when protective relays detect a problem.

What Size Wire for 80 Amp Breaker?

Electricians and specialists recommend utilizing wire gauges ranging from 2 AWG to 4 AWG for 80-ampere breakers. Because all domestic wires have a voltage rating of at least 600V in the US, only amperage matters when choosing a wire gauge. This rating is 220V in Bangladesh.

The gauge of a wire determines its diameter. Its diameter is represented by the number. A large number suggests a smaller wire. A low number, on the other hand, suggests a larger-sized wire. The following table will give you sizes of copper cable for the corresponding breakers. Aluminum wires will have different specifications.

Capacity of WiresWire Size
15 amps14-gauge wire
20 amps12-gauge wire
30 amps10-gauge wire
40 amps8-gauge wire
55 amps6-gauge wire
70 amps4-gauge wire
80 amps4-gauge wire
85 amps3-gauge wire
95 amps2-gauge wire

Why Wire Size is Important for Breakers?

Safety is the foremost reason for the importance of wire size. The total size of the wire decides whether or not the wire’s fitted conductors can manage the amperage that will flow through it. If a wire is not designed to sustain a specific amperage, it may accidentally melt and even ignite.

For this reason, we must be aware of the suitable wire size and its capacity to bear amperage load. As a general rule, thicker and larger wire diameters can handle higher amperage loads because they can moderate the excessive heat produced by the electricity flowing through the cable.

How to Calculate the Correct Size Wire for 80 amps?

The most difficult step of estimating the exact wire size is determining the size of the circuit breaker. You can rapidly determine the size of the wire once you know the size of the circuit breaker. However, in this scenario, you already know that the breaker is rated at 80 amps. Now you can find the wire size from the chart.

If the breaker size is not known, perform the following steps to evaluate it:

Step-1: Determine the total wattage of all of your home’s appliances.

Step-2: Divide that number by the voltage.

Step-3: The appropriate size of the breaker is obtained by multiplying the final amount by 125 percent.

Which Wire Is Better for 80 Amp Breaker?

The ampacity of aluminum wire is lower than that of copper wire. A gauge of copper wire can carry more current than a gauge of aluminum wire. If you have an option between the two, go with copper. Having said that, many individuals choose aluminum because it is less expensive. 

Factors to Consider While Selecting Cable for Your 80 Amp Breaker

Many technicians will repeat the guidelines of rules of thumb while selecting wire size and rely on them in all situations. But the factors that influence the wire size of your breaker are given below:

  1. The material of your conductor.
  2. The ambient rating of the conductor (wire) and its termination (connection) points.
  3. The type of load.
  4. Thermal de-rating conditions.
  5. Allowable voltage drop based on wire length.

Best Manufacturers of 80 Amp Breakers

The Square D by Schneider Electric Homeline 80 Amp Two-Pole Circuit Breaker is designed to protect your electrical system from overload and short-circuiting. This breaker works with Homeline load centers as well as CSED devices. The ANSI-certified and UL-listed item has a 120/240 VAC and 10,000 AIR rating.

Homeline circuit breakers are constructed with the same Square D brand quality that you have come to expect, but at a price that makes them the best value in their class. Circuit breakers of Homeline are the best in their class. Homeline products are designed particularly for the domestic market.

What Happens if You Use the Wrong Gauge Wire?

Using the incorrect wire gauge causes heat resistance, which can soon become a fire hazard. Notably, each cable is intended to accommodate a specified level of voltage that is optimal for a specific purpose. If you utilize an incorrectly sized wire, the huge levels of flowing electricity may cause it to melt.

Does Thicker Wire Increase Current?

The thick wire will conduct current more easily than the thin wire. Because a conductor’s resistance is inversely related to its cross-sectional area. The thicker the wire, the lower the resistance and hence the easier the current flows.

Frequently Asked Questions

Can you use aluminum wire for an 80 Amp breaker? 

If you must use aluminum, make sure it is of a greater gauge. For example, if you believe you can use a 6-gauge copper wire to fit an 80-amp circuit breaker, use 4 or 3-gauge wire for aluminum. The greater the diameter of the wire, the better. If you are unsure, get the largest wire you can afford.


An 80 amp service provides enough power to heat a small home without electricity. This is designed for heavy-duty applications. Circuit breakers require precise wire sizing since it determines how much electrical current can flow through them and how much resistance it has.

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