Proper sizing of generator wire is essential to ensure both safety and performance. Undersized wire can overheat, result in voltage drop, and even become a fire hazard. That’s where the Paige Wire Size Calculator comes in—a tool tailored to generators and their unique power delivery needs.
🔧 What Is the Paige Wire Size Calculator?
The Paige Wire Size Calculator is an online tool designed specifically for sizing electrical conductors between a generator and its load or transfer switch. It considers:
- Generator rated amperage
- Run length (distance from generator to load)
- Wire material (copper or aluminum)
- Acceptable voltage drop (typically 3%–5%)
- Whether the circuit is single-phase or three-phase
It outputs the minimum American Wire Gauge (AWG) or circular mil size needed for your setup.
✅ Why Proper Wire Sizing Matters
- Prevents overheating – Avoids insulation breakdown
- Reduces voltage drop – Keeps equipment operating properly
- Complies with NEC standards – Avoids code violations and fines
- Improves safety – Minimizes fire and electrocution risks
- Enhances performance – Guarantees reliable generator output
🛠️ How the Calculator Works
The calculator factors in:
- Current (Amps): Generator output specification
- Length of run (feet/meters): Distance through conductors
- Material (Cu/Al): Affects resistance and ampacity
- Voltage drop constraint: Typically set at 3% of generator voltage
- Phase configuration: Single-phase vs. three-phase wiring setup
Using these inputs, the calculator computes the required conductor size and suggests the nearest standard AWG or circular mil.
📝 How to Use the Paige Wire Size Calculator
1. Enter Generator Amperage
Common ratings: 30A, 50A, 100A, 200A, 400A, etc.
2. Enter Run Length
Distance in feet (or meters) from generator to load panel or transfer switch.
3. Choose Wire Material
Decide between Copper or Aluminum based on budget, flexibility, or code preference.
4. Set Voltage Drop Limit
Default is 3%, but tighter constraints like 1% can be used for sensitive equipment.
5. Select Phase Type
- Single‑phase for most residential systems
- Three‑phase for industrial or commercial setups
6. Click “Calculate”
Tool outputs the required AWG size, estimated voltage drop, and suggested conduit fill.
🔍 Sample Scenarios
Example 1: 50 Amp Generator, 100 ft Run, Copper, Single-Phase
- Amps: 50 A
- Length: 100 ft (200 ft round-trip)
- Result: Minimum 6 AWG copper to keep voltage drop <3%
Example 2: 200 Amp Generator, 300 ft Run, Aluminum, Three‑Phase
- Amps: 200 A
- Length: 300 ft
- Result: Roughly 500 kcmil aluminum needed to hold voltage drop <3%
🧠 Safety & Code Best Practices
- always round up to the next larger wire size
- Use copper for shorter runs or aluminum for long, high-amp connections
- Include equipment ground conductor
- Ensure conduit and connectors match wire size
- Check NEC ampacity tables (Table 310.16)
- Use GFCI protection if required by local code
- Keep documentation for inspections
⚙️ Additional Features You Might See
- Overcurrent protection sizing
- Conduit fill calculations
- Phase equation adaptation (single/three-phase)
- Metric outputs (mm² wire sizes for global use)
- Multiple circuit calculations at once
❓ 20 Frequently Asked Questions (FAQs)
1. What is the Paige Wire Size Calculator for?
It helps you choose the correct wire size between a generator and its load based on current, distance, and voltage drop.
2. Why is voltage drop a concern?
Excessive drop causes equipment inefficiency, overheating, and potential failure.
3. Should I use copper or aluminum wire?
Copper is more conductive but costlier; aluminum has higher resistance but is cheaper on long runs.
4. Is the calculator NEC-compliant?
Yes—it adheres to NEC voltage drop and ampacity guidelines.
5. Why round up wire size?
To account for future load changes, temperature, and safety margins.
6. Can I use it for solar inverter wiring?
Yes, if it’s an AC conductor sizing situation.
7. What phase types does it support?
Single-phase (240 V residential) and three-phase (400 V industrial) configurations.
8. Why include equipment grounding?
To comply with bonding/grounding requirements for safe fault protection.
9. Does it handle subpanel circuits?
Yes—just enter the circuit load and length like any other circuit.
10. How accurate is it?
Very—based on standardized voltage drop formulas and conductor resistance tables.
11. Do I need other tools?
Potentially a conduit fill calculator or torque settings for terminals.
12. Can it size for both hot and neutral conductors?
Yes—as long as current and configuration reflect actual loads.
13. What voltage drop is acceptable?
NEC recommends 3% max; equipment may require 1%.
14. What if I wire long runs underground?
Use larger wire and adjust for temperature and soil conditions.
15. Does altitude affect sizing?
Yes—higher altitude lowers conductor ampacity; consult NEC tables.
16. Can I handle multiple generators?
Yes—calculate each circuit separately.
17. Is conduit size important?
Yes—must be sized correctly for wire fill percentages.
18. Why not oversize too much?
Cost increases and rigidity make installation harder.
19. Should professionals double-check?
Absolutely—electricians and inspectors should review these calculations.
20. Is the tool free?
Yes—most online wire size calculators are free and accessible.
🏁 Final Thoughts
The Paige Wire Size Calculator is an essential tool for homeowners, contractors, and electricians sizing generator wiring correctly. By plugging in amperage, length, conductor type, voltage drop tolerance, and phase configuration, you can instantly get the recommended wire gauge that ensures safety, performance, and code compliance.