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Distribution Box Ground Wire Size Specification Table

The ground wire size for a distribution box depends on the overcurrent protection device and conductor material, with typical residential 100–200 amp services using 4 AWG copper or 2 AWG aluminum.

NEC Guidelines

The National Electrical Code (NEC) Article 250 governs grounding and bonding requirements. Specifically, Table 250. 122 provides the minimum equipment grounding conductor (EGC) size based on the rating of the overcurrent protection device (OCPD) protecting the circuit.

Copper and aluminum conductors have different sizing requirements due to conductivity differences, with aluminum typically requiring one size larger than copper for the same amperage. For example: 15–20 A circuits: 14 AWG copper, 12 AWG aluminum60 A circuits: 10 AWG copper, 8 AWG aluminum100 A circuits: 8 AWG copper, 6 AWG aluminum200 A service: 4 AWG copper, 2 AWG aluminum For OCPDs above 800 amps, the EGC must be at least 12. 5% of the area of the largest ungrounded conductor, ensuring adequate fault current path.

Practical Considerations for Distribution Boxes

Copper is preferred due to higher conductivity, corrosion resistance, and mechanical strength. Stranded or insulated green wire is commonly used for easier handling and secure connections.

For U

S distribution boxes, a 10 AWG copper wire is often the minimum for small units, while larger systems may require 6 AWG or even 4 AWG depending on the number of spindles, cable length, and total load. Ground resistance between all system parts should be less than 0. 1 ohm to ensure safety.

Summary

To select the correct ground wire size: Identify the OCPD rating for the circuit or service. Determine the conductor material (copper or aluminum).

Consult NE

C Table 250. 122 for the minimum EGC size. For typical residential 100–200 A services, use 4 AWG copper or 2 AWG aluminum.

Ensure proper connections and low resistance to maintain safety and code compliance. Following these guidelines ensures that the distribution box is safely grounded, protects equipment, and complies with NEC requirements.

Distribution Box Ground Wire Size Specification Table
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Technical note

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