So pay a consulting fee or buy a case of beer or a jug of hooch for a licensed local electrician to line out your project for you. You want to pass your inspection first time around but without spending more money and time than you have to. You need good advice before making electrical mods. My friends here in PM wish you well and would never knowingly mislead you but few of us (including me) are electrical professionals. While this is presented in tables, an informed judgement is still required. Wire Size 6 AWG to 300 MCM (Copper/Aluminum) Mounting Plug-On Used On Load Center, Panel Approval UL 489, CSA C22.2, FCC, EMC RoHS Compliant Applicable. OTH a 100 Amp service is defined by the breaker and the conductors it feeds have to meet code requirements for Ampacity, conduit fill, insulation, placement in construction, max ambient air temp, and other factors. In case that, downstream 100A feeders, even if not carrying the full dwelling unit load, need not be larger than the service/main feeder, so they can be 2-2-2-4 Al as well. In electrical practice the overcurret protection is intened to protect the conductors it feeds not the power consuming equipment. One corner case is where the dwelling unit service/main feeder itself is only 100A, so it could be wired with 2-2-2-4 Al. #4 may be technically adequate for your immediate application for a 100 Amp service for equipment that's seldom run to capacity but when feeding a pump or a heater for example #4 may not be suitable. Look up accaptable ampacity in the NEC and your local code for your application. They're satisfactory in most situatations but not always suited to every application. Often used for air conditioners, hot water heaters, and well pumps. Several brands also provide breakers with smaller sizes, 25 Amp Breakers which use the same wire size. Remember NEC and local code represents minimum standards. Used for high-demand appliances like electric stoves, ovens, and dryers. Then consider conductor size and conduit size. Some jurisdictions require upgrading of the branch circuit or sometimes even the whole system if any parts is sub-code. Maybe not in Wisconsin but certaily in warm climates. This wire size calculator will calculate the appropriate wire gauge for a circuit based on amps, voltage, distance, and load. Some jurisdictions have more stringent requirements for conductor ampacity and other electrical minutia.
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