Cable size for 100 A over 5 m, DC

For 100 A over 5 m on a 24 V DC supply, use at least 35 mm² (2 AWG) copper cable, protected by a 125 A fuse. Voltage drop: 2.7%.

Assumes copper cable clipped to a wall (or flexible battery cable for DC), 30 °C, PVC insulation. Change anything below.

The same current over other distances

Distance	Cable size	Voltage drop
1 m	25 mm² (4 AWG)	0.8%
2 m	25 mm² (4 AWG)	1.5%
3 m	25 mm² (4 AWG)	2.3%
5 m	35 mm² (2 AWG)	2.7%
10 m	70 mm² (2/0 AWG)	2.7%

35 mm²
2 AWG: 125 A
Fuse: 2.7%
Voltage drop: 6 m
2-core cable

Current at the end of the cableDistance (one way)m

Voltage

How the cable runs

Use at least35 mm²2 AWG

Fuse125 A

Voltage drop2.7% · 0.64 V

Current100 A

Cable carries up to200 A

The distance decides this size: 25 mm² would stay cool enough, but over 5 m it loses too much voltage.

Cores

2 cores (+ and −), or two single cables, red and black

Which cable

Tinned flexible battery cable (ISO 6722 / SAE J1127)

Vans and boats: resists vibration and corrosion.

Welding cable (H01N2-D)

Very flexible, for heavy battery and inverter leads.

Several circuits bundled together carry less each: allow for grouping (IEC 60364-5-52 Table B.52.17).

Guidance based on IEC 60364-5-52 for copper cables. Always check against your local rules (BS 7671, NEC, NF C 15-100, RTIEBT…) and the cable maker’s data.

Planning a whole solar system?Describe it and we size every cable, fuse and part, with a wiring diagram.