TryBuildCalcEV Charger Load Calculator (NEC 625.41 — Wire & Breaker Sizing)
Calculate your EV charger circuit instantly.
🕒 Last updated: August 29, 2026
Inputs
ℹ️Select your EVSE's charging level and amperage, or choose Custom to enter it directly.
ℹ️The EVSE's own nameplate rated continuous current — not the vehicle's onboard charger rating.
ℹ️Distance from the panel/breaker to the EVSE, one way — not round trip.
ℹ️The wire's own insulation rating (check the product's markings, e.g. THHN, THWN-2).
ℹ️Per NEC 110.14(C) — the breaker/panel/EVSE's own temperature rating. The calculator uses the lower of this and the insulation rating above.
Connection & Location
ℹ️Affects GFCI protection requirements per NEC 625.54.
Advanced (NEC Derating)
Cost
Recommended Circuit: 60A breaker, 6 AWG copper
For a 48.0A (11.5 kW) charger at 240V — sized by ampacity, not voltage drop
Ampacity Check
Design current: 60.0 A (125% continuous factor, NEC 625.41)
Minimum size by ampacity: 6 AWG
Derating factor applied: 1.00×
Final wire's derated ampacity: 65.0 A
Voltage Drop Check
Charger rated current: 48.0 A
Minimum size by voltage drop: 10 AWG
Allowed drop: 3.0%
Final wire's actual drop: 0.98% (2.36 V)
Circuit Summary
| System | 240 V, single-phase |
| One-way run length | 50.0 ft (15.2 m) |
| Connection / location | Hardwired, indoor |
Panel Impact (Informational)
| Service Size | % of Service Used by This Circuit |
|---|---|
| 100A | 60.0% |
| 125A | 48.0% |
| 150A | 40.0% |
| 200A | 30.0% |
| 225A | 26.7% |
This is a single circuit's share of a service, not a full load calculation — use the Panel Size Calculator to check your service has capacity for this plus everything else.
Assumptions Used
NEC 625.41 (125% continuous-load factor), NEC Table 310.16 ampacity, NEC 110.14(C) governing rating, NEC 240.4(D) small-conductor cap. Assumes a dedicated branch circuit (NEC 625.42) — not a shared/EMS-managed circuit. This is a reference estimate — confirm with a licensed electrician before installation.
Checking your panel has enough total capacity for this plus everything else? Panel Size Calculator →
Need to size the conduit for this and other conductors? Conduit Fill Calculator →
Looking for the verification checklist, reference tables, tips, or common mistakes?See the complete EV Charger Load Calculator.
General EV charger circuit estimate
This page gives the full combined result — design current, wire size, breaker size, GFCI requirement, and panel impact — from one set of charger and installation inputs.
It's the same calculator behind every other EV-charging variant on this site, just without a specific scenario pre-selected — useful for a general check before finalizing your actual charger and installation.
- Applies the NEC 625.41 125% continuous-load factor automatically.
- Reuses the same ampacity, voltage drop, and breaker sizing engine as the Wire Size Calculator for guaranteed consistency.
- Flags GFCI protection requirements by connection type and location.
EV Charger Circuit Formula: How Is It Calculated?
NEC 625.41's continuous-load treatment drives both the wire and breaker sizing.
Step 1 — Design Current
Design Current = Charger Rated Current × 1.25
Per NEC 625.41, EV charging equipment is always treated as a continuous load — this 125% factor applies regardless of how the charger is actually used.
Step 2 — Wire Size
Smallest AWG where: Derated Ampacity ≥ Design Current, AND
Voltage Drop at Charger Current ≤ Max Allowed %
The wire must satisfy both the design-current ampacity requirement and the voltage drop limit over the actual run length — whichever requires the larger wire governs.
Step 3 — Breaker Size
Recommended Breaker = smallest standard size ≥ Design Current
(capped by the wire's small-conductor OCPD limit, if lower)
Rounded up to a real NEC 240.6(A) standard breaker size, never a custom in-between value.
Worked Example
This example walks through your current inputs above, using the same steps as the Formula section.
Input Values Used
| Input | Value | Why it is used |
|---|---|---|
| Charger | 48.0A at 240V (11.5 kW) | Sets the base current before the continuous-load factor |
| Run Length | 50.0 ft | Sets the voltage drop check |
| Connection / Location | Hardwired, indoor | Sets the GFCI requirement |
Step 1 — Design Current
| Calculation | 48.0 × 1.25 |
| Design current | 60.0 A |
Steps 2-3 — Wire and Breaker Size
| Check | Result |
|---|---|
| Minimum size by ampacity (60.0A design current) | 6 AWG |
| Minimum size by voltage drop (3.0% max) | 10 AWG |
| Final wire (larger of the two) | 6 AWG |
| Breaker (design current rounded to standard size) | 60 A |
Therefore, for a 48.0A charger at 240V, you need 60A breaker, 6 AWG copper.
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Disclaimer: This calculator provides approximate results for planning and estimation purposes only. Actual requirements may vary based on site conditions, materials, workmanship, and local building regulations. Always consult a qualified engineer, architect, or construction professional before making final decisions.