wirenco 4/0 AWG XHHW-2 Aluminum Building Wire

Why I chose this conductor

I recently needed a short, heavy-gauge feeder for a residential service upgrade and opted for the wirenco 4/0 XHHW-2 aluminum in a 50‑foot cut. For this kind of work, aluminum makes sense: it’s lighter and far more cost-effective than copper at large sizes, and XHHW‑2 insulation is a workhorse for feeders in conduit, indoors or outdoors. A 50‑foot length was exactly right for my run from meter to main, with a little extra to spare for comfortable terminations.

Build quality and ratings

This wire uses a compact stranded aluminum conductor under black XHHW‑2 insulation. Compact stranding is a nice touch—it reduces the overall diameter versus standard concentric stranding, which helps with conduit fill. It also creates a slightly firmer feel during pulls and bends, which I’ll get into in a moment.

The insulation is appropriately tough. Jacket printing was crisp and consistent along the length in my coil, and the insulation took clean knife scores without tearing. XHHW‑2 is rated 90°C wet or dry, and this conductor carries a 205‑amp ampacity at 90°C. As always, real-world allowable ampacity is limited by the lowest temperature rating in the system—many lugs and breakers are 75°C—so plan feeders accordingly and apply the dwelling-service allowances where permitted by code.

A few certifications matter here:
- UL 44 compliance reassures me about the insulation system and its application scope.
- ASTM B800/B801 indicates the modern 8000‑series aluminum alloy and manufacturing for compact round conductors. This is the standard alloy family used for reliable aluminum feeders today.

At 0.238 lb/ft, the 50‑foot cut weighs roughly 12 pounds. That’s light enough for one person to manage a coil on a ladder or scaffold without drama.

Handling and pulling through conduit

If you’ve pulled big single conductors, you know the dance: keep the coil oriented, support the feed, and don’t fight friction you can prevent. The wirenco 4/0 XHHW‑2 behaves like a typical compact-stranded aluminum in this gauge—firm, a bit stubborn in tight sweeps, but predictable. A few notes from my pull:

• Use an oversized conduit if you have the option. The compact conductor helps, but 4/0 in multi-conductor runs still benefits from generous fill and large-radius sweeps. My pull in 2‑inch PVC with long-radius elbows went smoothly; I wouldn’t want to do the same run in 1‑1/2 inch with standard elbows.
• Don’t skimp on wire lube. Even with a short run, a liberal application reduced effort and protected the insulation from scuffing.
• Plan your bend geometry. Keep to the NEC minimum bend radius for 4 AWG and larger single conductors. The insulation and conductor tolerated careful forming, but this isn’t rope—force a tight bend and you’ll fight it the rest of the way.
• Keep the coil tangle-free. I set the coil on a lazy-susan style reel and peeled from the outside; that eliminated twist memory and made payout clean.

Overall, I’d call the handling temper “firm but fair.” The compact build gives you a smaller diameter, which is useful, but it also trades a bit of pliability versus a looser lay. That’s a fine trade for feeders.

Stripping, termination, and prep

Stripping the insulation was uneventful with a hooked blade and light scoring around the circumference, followed by a longitudinal slit. The insulation separates cleanly without gouging the aluminum strands if you take your time.

For terminations on aluminum:
- Use lugs listed for AL/CU and verify size compatibility for compact conductors.
- Apply an oxide-inhibiting compound, especially on older gear, and wire-brush the conductor lightly before insertion.
- Torque to spec. Over- or under-torque is where most aluminum termination issues begin.
- Respect temperature ratings on terminations; many are 75°C. The conductor may be 90°C rated, but the weakest link sets the limit.

Because the insulation is black, you’ll need to re-identify neutrals at the ends (permitted for sizes 4 AWG and larger). I used white heat-shrink for clarity. For equipment grounds, use a properly identified conductor—this single-conductor product is not a substitute for a green or bare ground.

Performance and use cases

Electrically and thermally, the wire performed as expected. Under load, there were no surprises: no noticeable warmth at terminations when torqued correctly, and the insulation showed no scuffs or abrasions after the pull. The compact diameter paid off in the panel gutter, where space is always at a premium.

This 4/0 XHHW‑2 is well-suited for:
- Service entrance conductors (in conduit) and meter-to-main feeders
- Subpanel feeders where aluminum is acceptable and weight/cost matter
- Outdoor and damp locations consistent with XHHW‑2 use
- Short utility lateral stubs in conduit where allowed by the AHJ

It’s less ideal for:
- Tight retrofit paths with multiple 90s and minimal working space—oversize the conduit or reconsider routing
- Applications demanding frequent flexing; this is a feeder, not a portable cord

Durability and finish

The jacket resisted abrasion during a couple of test pulls through scrap EMT with threaded couplings—no cuts, only light polishing of the surface. I didn’t observe any insulation chalking or flaking. Printing stayed readable after handling, which matters when inspectors want to read markings in place.

The compact stranding also makes for a tidy termination: the bundle seats well in set-screw and mechanical lugs without stray strand splay, and it accepts ferrules cleanly if you choose to use them where allowed.

Sizing, code, and planning considerations

A few planning points I found useful:
- Ampacity: 205 A at 90°C; check the 75°C column for terminations and apply any local allowances (for example, dwelling services and feeders under NEC 310.12 commonly use 4/0 aluminum for 200‑amp service).
- Conduit fill: Compact construction helps, but run the actual dimensions in your fill calculator. If you’re pulling multiple 4/0s plus a neutral and ground, jump up a trade size for sanity.
- Bend radius: Lay out your sweeps with generous radii; long sweeps make a huge difference.
- Length: The 50‑foot cut is a sweet spot for many meter-to-panel runs. If you need longer, confirm availability in other cut lengths or full reels to avoid extra splices.
- Identification: Black insulation simplifies stocking but requires re-identification for neutrals at terminations.

Pros and cons

Pros
- UL 44 and ASTM B800/B801 compliance inspires confidence
- Compact-stranded conductor reduces OD and helps with conduit fill
- Manageable weight at 0.238 lb/ft; a 50‑ft coil is easy to handle solo
- Tough XHHW‑2 insulation with clean stripping and good abrasion resistance
- Appropriate ampacity for common 200 A residential service feeders when installed per code

Cons
- Stiffer than standard stranding; plan for bigger sweeps and liberal lube
- Black-only insulation means re-identifying neutrals
- Tight conduit runs can be a wrestling match if you don’t oversize

The bottom line

The wirenco 4/0 XHHW‑2 is a solid, no‑nonsense aluminum feeder conductor. It checks the right boxes—current industry alloy, compact stranding, robust XHHW‑2 insulation, and the expected ampacity—without adding gimmicks. In my install, it handled predictably, terminated cleanly, and offered the diameter savings I wanted from compact construction. You do trade a bit of flexibility, so smart conduit design and pulling practice matter. If you size the raceway generously, use lubricant, and respect bend radius, it rewards you with an uneventful, professional install.

Recommendation: I recommend this conductor for residential and light commercial feeders where aluminum is appropriate and cost-effective, especially for 200‑amp service and similar applications. It’s certified, reasonably easy to work with given its size, and the compact build gives you a tangible advantage in conduit fill. Just plan your pathway thoughtfully and terminate it like aluminum deserves—clean, inhibited, and torqued to spec.