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A #3 copper conductor with an insulation factor of 75 and 90 degrees C is rated at 100 and 105 respectively. Even though the wire is rated at this amperage it can only be loaded to 80% capacity to conform with the electrical code requirements. To calculate if a 100 amp sub panel will be large enough, the connected load that you are going to connect to should be considered. If the total connected load is not over 80 and 84 amps respectively the #3 wire will pass inspection. Also check to see if the sub-panel that you are going to install is rated for 100% or 80% load rated.

A #2 copper conductor with an insulation factor of 75 and 90 degrees C

is rated at 115 and 120 amps respectively. The 80% de-rate still has to be applied. 115 x .8 = 92, 120 x .8 = 96.

A #1 copper conductor with an insulation factor of 75 and 90 degrees C

is rated at 130 and 140 amps respectively. The 80% de-rate still has to be applied. 130 x .8 = 104, 140 x .8 = 112.

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Warning

100A is a lot of current. It can easily overheat any bad connection. (I have a power supply that will put out 100A. I've melted screws and ignited pennies with it.) You need to consult code for a project this large. You must consult a wire size table and calculate the correct size cable for the run length. You cannot just stumble through it on your own. A mistake will start a fire.

Call en electrician and get an estimate. Go to the library and read about this, please. Negligence is fatal with electricity.

AnswerIf you have to ask, go with copper. Aluminimum is cheaper, but special precautions must be taken and special wiring devices must be used to be safe. You cannot use aluminimum like you would copper!

For copper, you need at least #2 wire for a run under 50ft.

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Q: What kind of wire do you need for a 100A subpanel?
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