Alternative energy power systems, components and design assistance.

JATS Alternative Power Company

Advanced Energy Group authorized dealer

 
 

Scroll Down or Select

2% Voltage Drop Max Ampacity Chart for

5% Voltage Drop Chart
Chart for 12 volt Copper & Aluminum
for 24v, 48v, 120v & 240v
systems Wire
2% Voltage Drop Chart For 12 volt Systems
Maximum distance in feet of various guage two conductor copper wire from power
source to load for 2% voltage drop in a 12 volt system. Do not exceed the 2% drop for
wire between PV modules and batteries. A 4 to 5% loss is acceptable between batteries
and lighting circuits in most cases, however the cost of the next larger wire size is
usually insignificant and increases efficiency.
Amps #14 #12 #10 #8 #6 #4 #2 #1/0 #2/0 #4/0
1 45 70 115 180 290 456 720 . . .
2 22.5 35 57.5 90 145 228 360 580 720 1060
4 10 17.5 27.5 45 72.5 114 180 290 360 580
6 7.5 12 17.5 30 47.5 75 120 193 243 380
8 5.5 8.5 11.5 22.5 35.5 57 90 145 180 290
10 4.5 7 11.5 18 28.5 45.5 72.5 115 145 230
15 3 4.5 7 12 19 30 48 76.5 96 150
20 2 3.5 5.5 9 14.5 22.5 36 57.5 72.5 116
25 1.8 2.8 4.5 7 11.5 18 29 46 58 92
30 1.5 2.4 3.5 6 9.5 15 24 38.5 48.5 77
40 . . 2.8 4.5 7 11.5 18 29 36 56
50 . . 2.3 3.6 5.5 9 14.5 23 29 46
100 . . . . 2.9 4.6 7.2 11.5 14.5 23
150 . . . . . . 4.8 7.7 9.7 15
200 . . . . . . 3.6 5.8 7.3 11

Top of Page
 5% Voltage Drop Table
The following tables represent the maximum one-way distance for various wire guage,
voltage and current combinations based upon a 5% voltage loss for 120v and 24v. Five
percent is acceptable in most low voltage systems, except 12 volt (see above). NOTE: To
obtain a 2% figure from these tables, divide the given distance shown in the table by 2.5.
For calculating distances for 48 volt systems, multiply the 24 volt distances by 2.
For 240 volt systems, multiply the 120 volt distances by 2.
Below stepped lines check ampacity. The (=) indicates over 1000 feet.

Top table = 120/240 volts;  Lower table = 24/48 volts;

or slide page to view voltage -------------------->

Below stepped lines check ampacity. The (=) indicates over 1000 feet.

To achieve maximum efficiency from your power system you do not want to under-size
your wire between various components. If in doubt use a larger wire size than the charts
below suggest. We will generally size the wire to maintain no more than a 2 - 3 percent
voltage drop regardless of the system voltage, however this factor is more critical on low
voltages. For 120/240 volts a maximum of five percent loss is acceptable unless specific
equipment dictates otherwise.
 The difference in cost of the next larger-size wire is usually insignificant to the overall
costs where performance may be affected over the life of the components.
In addition, improperly sized wire can shorten the life of your components.

**IMPORTANT**

Before using these tables, some calculations must first be performed by the system
designer to insure accurate current ratings and safety factors are used. For solar modules,
the UL-1703 standard requires the short circuit current (lsc) rating of the PV module be
multiplied by 125% before other factors are applied. This is because the PV module
electrical performance can increase above the factory rating due to the conbination of
increased operating temperatures and enhanced irradiances over 1000W/M2 (such as
edge-of-cloud effect).

NOTE
The "edge-of-cloud effect" is also a consideration
when sizing a charge/voltage controller for solar
modules. Use the short-circuit current rating to
determine the controller.

The NEC requires the short circuit current ratings of the PV module or array be
multiplied by 125% before calculating ampacities of any cable or overcurrent device.
This is in addition to the UL rquired 125%! This yields a multiplier of
(125%x125%=156%) or 1.56. Although this may seem redundant, good design practice
dictates both factors should be used when determining wire size from the solar array to
the battery.

Example
When calculating wire size from battery to load, multiply the load current by only 125%
(1.25).
Example:  A 24V solar array of four Solarex MSX-120 modules, 2 in series by 2 parallel 
modules located 30 ft. from the battery; lsc=7.60 A (one module); 7.60 x 2 = 15.2A (two
modules); 15.2A x 1.56 = 23.71A. Using the 24 volt table, locate a value equal to or
greater than 24 amps from the left column, follow a line to the right until a distance at or
above 30 ft. is found. For this example, using the 24 volt table, we find 25 amps at 36 feet
to be the best selection (for not more than 5% loss) indicating a wire size of #8 AWG.

For larger batteries and  inverters (battery to inverter cable connections)

a  minimum 4/0 cable is recommended.

Top of Page
 Maximum Ampacity for Copper and
Aluminum Wire
Wire Size Copper Aluminum
14 25 .
12 30 25
10 40 35
8 55 45
6 75 60
4 95 75
2 130 100
1 150 115
1/0 170 135
2/0 265 150
4/0 360 205

NEC allows rounding up cable ampacity to next standard fuse or breaker.

Top of Page

Go back to solar power system sizing

© JATS Alternative Power Company - All rights reserved

Site Index
Site Index
Basics
Basics
Sizing
Sizing
Resources
Resources
Equipment
Equipment
Contact Us
Contact Us
Opportunities
Opportunities
A complete
organized listing
of all page links
A complete organized listing of all page links
Learn the basics of solar and wind power systems
Learn the basics of solar and wind power systems
Use our design tools to estimate your system size and cost
Use our design tools to estimate your system size and cost
View state incentives and other energy related links
View state incentives and other energy related links
View all equipment selections from leading manufacturers
View all equipment selections from leading manufacturers
Provides company contact information for phone, fax or email
Provides company contact information for phone, fax or email
Join our growing network of professional dealers
Join our growing network of professional dealers