Wiring
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WIRING ACCESSORIES & BULK WIRE
We carry high quality bulk wire for use as solar module interconnects, to connect wind machines and hydro units to the system and for general wiring needs. We also stock a variety of assembled battery-to-inverter and battery interconnect cables that come with lugs and heat shrink. Bulk battery cable is available with and without UL listing for those who wish to assemble their own battery cables. Custom cables are available by special order.
For meter wire, look in the meter section. For water pumping wire, see the water pumping section.
We have included a number of handy charts in this section to help you use the correct size wire for your application.
The 12 volt, 2% Wire Loss Chart allows you to find the size wire needed for your distance and amperage. Calculate the maximum amps that the wire will carry and find that amperage in the left-most column (round up). Follow the row across until you find the one-way distance (length of the needed wire). Go to the top of the column to find the size wire needed. This chart is figured for 12 volt systems. For 24 volt systems, you can go twice as far with the same size wire as in 12 volt systems.
The Maximum Ampacity Chart shows the maximum allowable ampacity wire can carry safely. (There is no provision for wire loss in this chart.) Wire rating is affected by temperature. If your application will be in a high temperature area, use the Temperature Correction Factors Chart to adjust the maximum ampacity for high temperature. Use the Recommended Cable, Fuse & Breaker Size Chart to find the appropriate cable, fuse and breaker sizes to use with the various Trace inverters. Cable sizes listed are minimums, and larger cable may be needed for lengths greater than 3 feet. Additional information is available in your inverter’s manual.
12 VOLT 2% WIRE LOSS CHART
Maximum distance one-way in feet of various gauge 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.
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 |
15 |
22.5 |
35.5 |
57 |
90 |
145 |
180 |
290 |
10 |
4.5 |
7 |
12 |
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 |
Maximum Ampacities for Copper & Aluminum Wire
Allowable ampacities of conductors (wires) in conduit, raceway, cable or directly buried, based on ambient temperature of 30°C (86°F). NEC allows rounding up cable ampacity to next size standard fuse or breaker.
Wire Size |
Copper Conductor Temp Rating |
Aluminum Cond. Temp. Rating |
75°C (167°F) |
90°C (194°F) |
75°C (167°F) |
90°C (194°F) |
75°C (167°F) |
*14** |
20 |
25 |
|
|
*12 |
25 |
30 |
20 |
25 |
*10 |
35 |
40 |
30 |
35 |
8 |
50 |
55 |
40 |
45 |
6 |
65 |
75 |
50 |
60 |
4 |
85 |
95 |
65 |
75 |
2 |
115 |
130 |
90 |
100 |
1 |
130 |
150 |
100 |
115 |
1/0 |
150 |
170 |
120 |
135 |
2/0 |
175 |
195 |
135 |
150 |
3/0 |
200 |
225 |
155 |
175 |
4/0 |
230 |
260 |
180 |
205 |
|
|
Temperature Correction Factors
For ambient temps. above 30°C (86°F), multiply the allowable ampacities shown above by the appropriate factor shown below:
Temperature Range |
75°F insul |
90°F insul |
31-35C |
87-95F |
0.94 |
0.96 |
36-40C |
96-104F |
0.88 |
0.91 |
41-45C |
105-113F |
0.82 |
0.87 |
46-50C |
114-122F |
0.75 |
0.82 |
51-55C |
123-131F |
0.67 |
0.76 |
56-60C |
132-140F |
0.58 |
0.71 |
For Code Installations
*The 1999 NEC, sec 240-3, specifically states that the overcurrent protection shall not exceed 15A for # 14 wire, 20A for # 12 wire and 30A for #10 wire. |
Recommended Cable, Fuse & Breaker Size for Trace Inverters
Trace Model |
Max Continuous Amps |
Breaker Size Amps |
Class T Fuse Size |
Minimum Cable Size |
DR1512 |
160 |
175 |
200 |
2/0** |
DR1524 |
80 |
175 |
200 |
2/0 |
DR2412 |
240 |
250* |
300 |
4/0** |
DR2424 |
120 |
175 |
200 |
2/0** |
DR3624 |
180 |
250 |
400 |
4/0 |
SW2512 |
260 |
250* |
400 |
4/0** |
SW4024 |
214 |
250* |
400 |
4/0 |
SW4048 |
107 |
175 |
200 |
2/0** |
SW5548 |
147 |
175 |
200 |
2/0** |
U2624 |
139 |
175 |
200 |
2/0 |
U2548 |
67 |
175 |
200 |
2/0 |
* May not allow continuous operation at full rate power.
**Use larger cables for longer wire runs. See Trace manual for more info.
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