EV charger wire gauge, also referred to as EV charger diameter, or wire size is the the thickness of wires used in an electrical vehicle branch circuit. EV charger wire size is measured in American Wire Gauge or sometimes in millimeters squared (mm²).
According to the National Electrical Code (NEC), the correct wire gauge for your EV charger installation is determined by the amperage rating of the dedicated EV charger circuit breaker. This specification is crucial, as it directly influences both the efficiency and safety of your EV charging system.
Selecting the correct wire gauge for your EV charger installation is essential to safely handle continuous loads of EV charging. It ensures safe current flow, minimizes energy loss, prevents overheating, reduces the risk of electrical fires, and maintains optimal charger performance throughout its lifespan.
Table of Contents
EV Charger Wire Gauge Chart
The EV Charger Wire Gauge Chart below lists common electrical vehicle branch circuit wire sizes for Level 1 and Level 2 EV chargers. It shows the wire image and specifies the appropriate wire gauges (AWG) for different power levels and current draws.
Common EV Charger Wire Gauge
EV charger wire gauge is determined by the amperage of the circuit breaker in an electric vehicle branch circuit, the table below summarizes common EV charger wire gauge used in EV charger installations.
| EV Charger Rating (Continuous Loads) | Power Rating of EV Charger (kW) | EV Charger Dedicated Breaker Size (20/80 Rule) | Hot Wire Gauge (AWG) (Copper) | EV Charger Wire Size (mm²) |
|---|---|---|---|---|
| 12 Amp | 2.88 kW | 15 Amp | 14 | 2.08 mm² |
| 16 Amp | 3.84 kW | 20 Amp | 12 | 3.31 mm² |
| 20 Amp | 4.80 kW | 25 Amp | 10 | 5.26 mm² |
| 24 Amp | 5.76 kW | 30 Amp | 10 | 5.26 mm² |
| 28 Amp | 6.72 kW | 35 Amp | 8 | 8.37 mm² |
| 32 Amp | 7.68 kW | 40 Amp | 8 | 8.37 mm² |
| 36 Amp | 8.64 kW | 45 Amp | 6 | 13.3 mm² |
| 40 Amp | 9.60 kW | 50 Amp | 6 | 13.3 mm² |
| 48 Amp | 11.52 kW | 60 Amp | 4 | 21.2 mm² |
| 56 Amp | 13.44 kW | 70 Amp | 4 | 21.2 mm² |
| 64 Amp | 15.36 kW | 80 Amp | 3 | 26.7 mm² |
| 72 Amp | 17.28 kW | 90 Amp | 2 | 33.6 mm² |
| 80 Amp | 19.20 kW | 100 Amp | 2 | 33.6 mm² |
Here are some common usages for the various EV charger wire gauges:
Plug-In EV Charger Wire Sizes
The National Electrical Code (NEC) specifies that the maximum amperage for a plug-in EV charger is 40 amps, requiring a 50-amp circuit breaker. Plug-in chargers are limited by the capacity of NEMA outlets and the safety of removable connections.
Recommended Wire Sizes for Plug-In EV Chargers
| Plug-In EV Charger Rating (Amps) | Power Rating (kW) | Breaker Size (Amps) | Wire Gauge (AWG) | Wire Size (mm²) | NEMA Outlet |
|---|---|---|---|---|---|
| 12 A | 2.88 kW | 15 A | 14 | 2.08 mm² | NEMA 5-15 (120V) |
| 16 A | 3.84 kW | 20 A | 12 | 3.31 mm² | NEMA 5-20 (120V) |
| 20 A | 4.80 kW | 25 A | 10 | 5.26 mm² | NEMA 6-20 (240V) |
| 24 A | 5.76 kW | 30 A | 10 | 5.26 mm² | NEMA 6-30 (240V) |
| 32 A | 7.68 kW | 40 A | 8 | 8.37 mm² | NEMA 14-50 (240V) |
| 40 A | 9.60 kW | 50 A | 6 | 13.3 mm² | NEMA 14-50 or 6-50 |
To assist you with the installation process of plug-in EV charger outlets, we recommend checking out our comprehensive guide on installing NEMA outlets for plug-in EV chargers. This guide covers everything you need to know, including how to select the correct outlet for your charger’s amperage, determine the proper dedicated circuit breaker size, choose the right outlet wiring and wire gauge, and provide installation tips. By following this guide, you’ll ensure that your setup meets safety standards and is ready for reliable, daily use.
Hardwired EV Charger Wire Sizes
Hardwired chargers are permanently installed, providing higher power capacity and supporting faster charging rates compared to plug-in chargers. They are ideal for chargers exceeding 40 amps or when a clean, permanent setup is desired.
Recommended Wire Sizes for Hardwired EV Chargers
| Hardwired EV Charger Rating (Continuous Loads) | Power Rating of EV Charger (kW) | EV Charger Dedicated Breaker Size (20/80 Rule) | Hot Wire Gauge (AWG) (Copper) | EV Charger Wire Size (mm²) |
|---|---|---|---|---|
| 12 Amp | 2.88 kW | 15 Amp | 14 | 2.08 mm² |
| 16 Amp | 3.84 kW | 20 Amp | 12 | 3.31 mm² |
| 20 Amp | 4.80 kW | 25 Amp | 10 | 5.26 mm² |
| 24 Amp | 5.76 kW | 30 Amp | 10 | 5.26 mm² |
| 28 Amp | 6.72 kW | 35 Amp | 8 | 8.37 mm² |
| 32 Amp | 7.68 kW | 40 Amp | 8 | 8.37 mm² |
| 36 Amp | 8.64 kW | 45 Amp | 6 | 13.3 mm² |
| 40 Amp | 9.60 kW | 50 Amp | 6 | 13.3 mm² |
| 48 Amp | 11.52 kW | 60 Amp | 4 | 21.2 mm² |
| 56 Amp | 13.44 kW | 70 Amp | 4 | 21.2 mm² |
| 64 Amp | 15.36 kW | 80 Amp | 3 | 26.7 mm² |
| 72 Amp | 17.28 kW | 90 Amp | 2 | 33.6 mm² |
| 80 Amp | 19.20 kW | 100 Amp | 2 | 33.6 mm² |
For those installing a hardwired EV charger, we recommend checking out our comprehensive guide on hardwired EV charger installation. This guide covers essential topics like selecting the correct wire gauge for your charger’s amperage, determining the appropriate dedicated circuit breaker size, and following expert installation practices. By using this guide, you’ll ensure that your hardwired EV charger is safely installed, adheres to electrical codes, and is ready for reliable, high-performance use.
Level 1 EV Charger Wire Size
12-Gauge Wire (12 AWG): Ideal for Level 1 EV chargers operating at 120V.
Level 1 EV chargers are ideal for home use when only a standard 120V outlet is available. They provide slower charging speeds but are convenient for overnight charging of smaller EV batteries or plug-in hybrid vehicles.
With a NEMA 5-15 outlet (12 amps continuous load), it supports up to 1.3 kW. With a NEMA 5-20 outlet (16 amps continuous load), it supports up to 1.7 kW. This setup is perfect for slow, steady charging.
Level 2 EV Charger Wire Size
Level 2 EV chargers operate at 240V, offering significantly faster charging speeds than Level 1 chargers, making them ideal for daily at-home use. These chargers require higher amperage and thicker wires to accommodate the increased power demand and the continuous load of Level 2 charging.
Wire Size Recommendations for Level 2 EV Chargers
| Level 2 EV Charger Rating (Continuous Loads) | Power Rating of EV Charger (kW) | EV Charger Dedicated Breaker Size (20/80 Rule) | Hot Wire Gauge (AWG) (Copper) | EV Charger Wire Size (mm²) |
|---|---|---|---|---|
| 12 Amp | 2.88 kW | 15 Amp | 14 | 2.08 mm² |
| 16 Amp | 3.84 kW | 20 Amp | 12 | 3.31 mm² |
| 20 Amp | 4.80 kW | 25 Amp | 10 | 5.26 mm² |
| 24 Amp | 5.76 kW | 30 Amp | 10 | 5.26 mm² |
| 28 Amp | 6.72 kW | 35 Amp | 8 | 8.37 mm² |
| 32 Amp | 7.68 kW | 40 Amp | 8 | 8.37 mm² |
| 36 Amp | 8.64 kW | 45 Amp | 6 | 13.3 mm² |
| 40 Amp | 9.60 kW | 50 Amp | 6 | 13.3 mm² |
| 48 Amp | 11.52 kW | 60 Amp | 4 | 21.2 mm² |
| 56 Amp | 13.44 kW | 70 Amp | 4 | 21.2 mm² |
| 64 Amp | 15.36 kW | 80 Amp | 3 | 26.7 mm² |
| 72 Amp | 17.28 kW | 90 Amp | 2 | 33.6 mm² |
| 80 Amp | 19.20 kW | 100 Amp | 2 | 33.6 mm² |
EV Charger Ground Conductor Size
The size of an EV charger ground conductor is typically based on the dedicated circuit breaker size, as indicated in NEC Table 250.122. This ensures they can handle fault currents without damage.
| EV Charger Rating (Continuous Loads) | EV Charger Dedicated Breaker Size (20/80 Rule) | Grounding Conductor (Copper) | Grounding Conductor (Aluminum) |
|---|---|---|---|
| 12 Amp | 15 Amp | 14 AWG | 12 AWG |
| 16 Amp | 20 Amp | 12 AWG | 10 AWG |
| 20 Amp | 25 Amp | 10 AWG | 8 AWG |
| 24 Amp | 30 Amp | 10 AWG | 8 AWG |
| 28 Amp | 35 Amp | 10 AWG | 8 AWG |
| 32 Amp | 40 Amp | 10 AWG | 8 AWG |
| 36 Amp | 45 Amp | 10 AWG | 8 AWG |
| 40 Amp | 50 Amp | 10 AWG | 8 AWG |
| 48 Amp | 60 Amp | 10 AWG | 8 AWG |
| 56 Amp | 70 Amp | 8 AWG | 6 AWG |
| 64 Amp | 80 Amp | 8 AWG | 6 AWG |
| 72 Amp | 90 Amp | 8 AWG | 6 AWG |
| 80 Amp | 100 Amp | 8 AWG | 6 AWG |
For more detailed installation guidelines, refer to our EV Charger Earthing Guide.
Factors to Consider When Choosing EV Charger Wire Gauge
Electric Vehicle Branch Circuit Load (Charging Station Power)
The primary factor influencing your choice of EV charger wire gauge is the electrical load of your EV branch circuit. To determine the appropriate wire gauge, you must first understand the total electrical load of your EV charger. According to the National Electrical Code (NEC), the total current draw must be less than 80% of the circuit breaker’s rated limit due to derating requirements for continuous loads.
The higher the electric vehicle branch circuit load (charging station power), the larger the cable size should be to support the electrical current flowing to the charger.
EV Charger Circuit Breaker Size.
The breaker size for an EV charger installation is determined by the amperage of the EV charger, following the 80/20 rule, which ensures the system is sized to handle continuous loads safely. According to this rule, the breaker should be rated at 125% of the charger’s maximum amperage to account for potential long-duration charging.
Distance from Electrical Panel
The distance between the EV charger’s electrical panel and the EV charger itself influences the choice of cable used in EV charger installations. The greater the distance, the larger the cable size needed to compensate for voltage drops (a voltage drop of no more than 3% is generally recommended).
EV charging voltage drops occur when the electric vehicle branch circuit current travels through a long cable. Using an inadequate cable size can result in inefficient and potentially hazardous EV charging. To mitigate voltage drops, we recommend using an EV charging subpanel.
Future Electric Vehicle Branch Circuit Expansion
If you plan to expand your electrical vehicle branch circuit, it’s wise to install a wire gauge that accommodates future growth, for example when installing a Level 1 EV charger, but in the future, you plan to install a Level 2 EV charger it wise to use Level 2 EV charger wire size to save you from costly upgrades down the road.
EV Charging Cable Number of Conductors
The number of conductors in an EV charger cable depends on the type of EV charger installation.
For single-phase EV charger installations, three conductors are necessary: phase, neutral, and ground as shown in the single-phase electric vehicle branch circuit below:
For three-phase EV charger installations, four conductors are required: two phases, neutral, and ground as shown in the three-phase electric vehicle branch circuit below:
These conductors are bundled within a single cable and are typically composed of multiple metal strands to ensure flexibility and durability. The choice between single-phase and three-phase installations depends on your EV charger branch circuit and the specifications of the charging station.
Learn more about wiring an electric vehicle branch circuit:
Copper vs. Aluminum EV Charger Wiring
When considering EV charger installations, copper wiring surpasses aluminum due to its superior thermal properties, which significantly impact performance and safety.
Here’s why we recommend copper wire for EV charger installation:
- Superior Conductivity: Copper offers significantly better conductivity than aluminum. This translates to lower resistive losses, minimizing heat generation within the cable. This is crucial for EV chargers that deliver high currents for extended periods.
- Enhanced Safety: Lower heat generation with copper reduces the risk of overheating and potential fire hazards, especially during longer EV charging sessions.
- Reliable Connections: Copper’s superior malleability allows for tighter and more reliable connections at the charger terminals, further enhancing safety and preventing power loss.
Conclusions
In conclusion, selecting the appropriate EV charger wire gauge is crucial for ensuring the efficient and safe operation of your electric vehicle charging station. Consider factors such as the charging station power requirements, distance from the electrical panel, potential future expansions, and the choice between copper and aluminum wiring. By carefully evaluating these considerations, you can make an informed decision that optimizes performance while maintaining safety standards for your EV charger installation.
About the Author: James Ndungu
James Ndungu, founder and editor-in-chief of Electric Vehicle Geek, brings over five years of hands-on experience in Electric Vehicle Supply Equipment (EVSE) selection, permitting, and installation. He specializes in assisting businesses and homeowners in the United States with a seamless transition to electric vehicles.
As a certified EV charger installer and holder of advanced certifications, including the EVITP (Electric Vehicle Infrastructure Training Program), Diploma in Electric Vehicle Technology, and Diploma in Engineering Fundamentals of Electric Vehicles, I provide expert guidance and in-depth reviews on the latest EV charging equipment.
