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Battery cable sizing impacts an electrical system's performance and safety. Inadequate cable size can reduce effectiveness, cause voltage drops, and cause overheating. Proper battery cable sizing offers the best power transmission, extends battery life, and protects against electrical problems. The cable size must comply with safety regulations to ensure safety and smooth current flow. You can use a battery cable size chart to find the correct cable gauge for your application.
Jackery Solar Generators are essential home backup solutions that reduce the dependency on grid energy and use clean, renewable energy to run your household appliances. The cables compatible with Jackery Solar Generators ensure your device gets the optimal charge it needs. If you buy the complete Jackery Solar Generator bundle, you will get all the necessary cables and connectors for adequate charging.
AI Takeaways
- Battery cable parts are also referred to as battery leads and are mainly composed of copper and aluminum.
- A regular gauge reading is between 13 and 15 volts, and a reading of 12 while the battery runs indicates a problem.
- The cable thickness is measured using a standard American Wire Gauge (AWG) method, which ranges from 0000 to 40 and handles up to 302 to 0.0137 amperes, respectively.
- You can calculate the amperage of your device by dividing the appliance wattage by its voltage.
- Is the battery cable size too small or too big.
What are the Types of Battery Cables?
Battery cables are categorized by their insulation types, such as SGT, SGX, marine, fuse link, OFC, and CCA. A battery cable is a single conductor wire composed of heavy gauge copper. It is insulated with PVC and used to safely link the vehicle’s battery with the automotive parts. Battery cable parts are also referred to as battery leads. It features a positive lead connecting to the ignition and a negative lead connecting to the chassis. Here are some types of battery cables:
- SGX battery cable
- SGT battery cable
- Marine battery cable
- Fuse link or fusible link
- OFC (Oxygen Free Copper)
- CCA (Copper Clad Aluminum)
SGX Battery Cable
The SGX battery cable is flexible and suitable for high-temperature applications. It is soft-annealed, has chemically cross-linked polyolefin insulation, and has a temperature rating from -40°C to +125°C (-40°F to +257°F). The insulation trade-off is thicker and stiffer, with a high strand count. SGX can be a good choice if you need a high-temperature rating.
SGT Battery Cable
The SGT battery cable has a THHN-type wiring coating, particularly thermoplastic PVC insulation. THHN stands for thermoplastic high heat-resistant Nylon-coated. The insulated SGT battery cable is rated at 50 volts for 85 or 105°C (185 or 221°F). The strand count is low because the strands are more significant, which makes the wire stiffer to stay where you put it and can be bent around tight corners.
Marine Battery Cable
Marine wires are rated for high temperatures and wet or submerged applications. These wires are usually self-extinguishing and have a marine rating as the Coast Guard legal requirement. If a wire does not have a marine rating, building a cable out of it is not recommended. The voltage rating of marine battery cable is 600 volts, and its temperature rating is +105°C (221°F) for dry and +75°C (167°F) for wet.
Fuse Link or Fusible Link
A fuse or fusible link is a slow-acting fuse that looks like a wire. It has high-temperature insulation that won’t burn even if the fuses open. The fuse link is commonly used in alternator wires. It protects from catastrophic failure of the alternator diode, as the alternator wire would melt without the fuse link. Other use cases of fuse links are when the wire intake grid heater relays on engines.
OFC (Oxygen Free Copper)
A standard oxygen-free copper wire is 99.95% copper, and an OFC is as expensive as a standard cable of the same size. Stereo shops sell OFC wires to connect a high-power ampere, and a good-quality OFC wire is SAE-approved.
CCA (Copper Clad Aluminum)
A copper-clad aluminum wire is a copper-plated aluminum that is two sizes larger to have an optimal level of conductivity, as aluminum has 60% of the conductivity of copper.
What are the Types of Battery Gauges or Size Cables?
A battery gauge or voltage gauge is a device used to measure battery voltage. Some gauges come with numbers, and others display an average position of the battery when the needle is placed in the middle of the gauge. If a number on the gauge shows a reading of 12 while the engine is running, it indicates a problem. The standard gauge reading should be above 13 and below 15 volts. Here is a list of some battery gauges:
- 10 Gauge wire
- 8 Gauge wire
- 6 Gauge wire
- 4 Gauge wire
- 2 Gauge wire
- 1 Gauge wire
- 1/0 Gauge
- 2/0 Gauge
- 3/0 Gauge
- 4/0 Gauge
10 Gauge wire: It is used for starter trigger wires, alternators (low power), and accessory leads.
8-gauge wire: This black wire, rated for 40 amps, is used for low-power alternators and accessory leads.
6 gauge wire: This wire is suitable for 55 amps and is also black. It is used in stock alternators, accessory leads, battery cables for ATVs and subcompacts, and golf cart wiring.
4 Gauge wire: A 4 gauge American wire is used for car battery cables, audio systems, and other residential and industrial applications. It is rated up to 160 amperes and is suitable for alternator wiring.
2 Gauge wire: A 2 gauge wire is commonly used in high-amperage capacity applications such as heavy machinery, industrial equipment, power converters, winches, etc. According to standard ampacity ratings, it can carry about 115 amps with 60°C (140°F) insulation, 130 amps with 75°C (167°F) insulation, and 150 amps with 90°C (194°F) insulation.
1 Gauge wire: A 1 gauge wire can be used for 6-cylinder or V8 automotive engines, power converters, and alternators in the range of 200 amperes.
1/0 Gauge: A 1/0 gauge wire is heavy-duty and is used in various electrical applications, such as 6-cylinder engines, stock V8s, welding equipment, marine batteries, solar panel and wind turbine installations, etc. For common insulation types, a 1/0 copper wire amperage capacity is 150A at a temperature of 75°C (167°F).
2/0 Gauge: A 2/0 gauge wire is more significant than a 2 AWG wire used in power distribution, transmission, bonding, and grounding. It has a diameter of 9.27mm and an ampere capacity of 135 ampere at 60°C (140°F). It is a low-resistance and high-ampacity wire and cable for high-compression engines, diesel engines, and large RV power converter house batteries.
3/0 Gauge: As set forward by the National Electrical Code (NEC), a 3/0 gauge wire is used for marine and diesel engines. It can be installed in dry and damp locations and operated in temperatures up to 90°C (194°F) and in wet locations at 75°C (167°F). The wiring is used in raceways that are exposed to sunlight.
4/0 Gauge: With a rating of 230 amperes at 75oC (167°F), the 4/0 gauge wire is used for high-power alternative battery banks. The rating can vary with copper or aluminum conducting material and insulation.
Why is Battery Cable Sizing Important?
Proper cable size for electrical applications is essential for several reasons. Cable sizing standards and regulations must comply with safety guidelines. Proper battery cable sizing reduces the risk of electrical accidents due to overheating, minimizes voltage drops, and more. To optimize the performance of electrical systems, the bulk wire should be considered carefully, as with a proper cable size, the power flow will be smooth.
An appropriately sized cable prevents anticipated future breakdowns, ultimately enhancing the machine's productivity. Proper battery cable sizing prevents electrical failure, mitigates worker risk, and protects industries' assets. It also helps increase the lifespan of machinery and enables appliances to operate without strain under normal working conditions.
What is a Wire Gauge Sizes Chart?
A wire gauge size chart, usually based on American Wire Gauge (AWG), is a standardized table that shows a wire’s size, its ability to carry current (ampacity), and its electrical resistance. If you want to choose a wire gauge size, you should look at the side of the wire for printing or a stamp in the connector that tells the size.
Different stranding styles might indicate that no one size fits all. However, it is advisable to choose the larger wire size. A gauge of wire refers to its thickness and is represented by small numbers indicating thicker wire gauges and large numbers signifying thinner wires.
The cable thickness is measured using a standard American Wire Gauge (AWG) method, which ranges from 0000 to 40 and handles up to 302 to 0.0137 amperes, respectively. Below is the wire gauge size chart, which helps measure the wire size in terms of thickness.
|
Wire Gauge Size |
Copper Conductor Diameter |
Overall Outside Diameter with Insulation |
|
8 |
0.143-0.165 inch (3.63-4.19 mm) |
0.218-0.270 inch (5.54-6.86 mm) |
|
6 |
0.181-0.200 inch (4.60-5.08 mm) |
0.305-0.340 inch (7.75-8.64 mm) |
|
4 |
0.219-0.252 inch (5.56-6.40 mm) |
0.343-0.405 inch (8.71-10.29 mm) |
|
2 |
0.289-0.326 inch (7.34-8.28 mm) |
0.418-0.475 inch (10.62-12.07 mm) |
|
1 |
0.341-0.361 inch (8.66-9.17 mm) |
0.479-0.520 inch (12.17-13.21 mm) |
|
1/0 (0) |
0.348-0.405 inch (8.84-10.29 mm) |
0.500-0.565 inch (12.70-14.35 mm) |
|
2/0 (00) |
0.429-0.460 inch (10.90-11.68mm) |
0.568-0.655 inch (14.43-16.64 mm) |
|
3/0 (000) |
0.485-0.510 inch (12.32-12.95mm) |
0.641-0.670 inch (16.28-17.02 mm) |
|
4/0 (0000) |
0.555-0.580 inch (14.10-14.73mm) |
0.695-0.741 inch (17.65-18.82 mm) |
What is Battery Cable Size Chart?
A battery cable size chart is a way to visualize the effects of a component. A battery cable size chart helps you to determine the correct cable size required for your application and indicates what cable you need in your system. Below are the steps to help you know how to use the battery cable chart:
Step 1: Know your DC Amp Requirement: First, locate the current flow (in ampere) at the chart's top.
Step 2: Consider The Type Of Circuit You Have: Next, you need to select the correct circuit type from the two types: non-critical and critical. These types are mainly found in RV and marine applications. Some examples of essential kinds of circuits include solar panel feed, operational electronics, bilge blowers, and non-critical circuit examples, such as general lighting, appliances, pumps, etc.
Step 3: Determine Your Cable Length Needed: Generally, a cable is twice the length of an application. For example, if your application is 20 feet long, you will need a 40-foot wire, which is 20 feet for positive and 20 feet for negative.
Step 4: Find Your Correct Cable Size: Once you determine the DC ampere, you can intersect it with the total cable length range and identify the color code.
Step 5: Cable Conversion Table: Lastly, match the color code to the cable chart and find the correct circle specifications and size.
What is the Battery Cable Amperage Capacity Chart?
A battery cable amperage capacity chart, or wire gauge chart, is a tool that shows the relationship between the American Wire Gauge (AWG) of a battery cable and the amount of electrical current (amperage) it can safely carry.
Amperage is the unit of current that the appliances need in a certain amount to function when connected to a battery. For example, an inverter might use 150 amps of current, whereas a bulb might need only 10 amps to function. The maximum amperage is calculated by knowing the total current drawn by all the appliances. You can also see the amperage of your device by dividing the appliance wattage by its voltage. A voltage is produced when a positively charged terminal works with a negatively charged terminal. Voltage allows the electrons to move from the negative to the battery's positive end.
A battery cable amperage capacity chart determines the appropriate size for battery cables. It first calculates the device's amperage based on its wattage and then tells how to match the cable size according to the appliance's voltage. Cable sizing involves three critical parameters: amperage, cable diameter, and voltage.
The amperage capacity chart also showcases the relationship between cable size and amperage. To use the battery cable amperage capacity chart, select a battery cable size on the left and amperage from the column on the top. When you intersect the cable size and amperage, you can get the maximum length of wire that you can use. For example, a 6-gauge wire in a 12V battery cable size chart would carry 50 amperes in a maximum of 11.8ft.
|
Battery Cable Size |
50 Amps |
100 Amps |
150 Amps |
200 Amps |
300 Amps |
|
6 AWG |
11.8ft |
5.9ft |
4.4ft |
2.9ft |
2.2ft |
|
4 AWG |
18.8ft |
9.4ft |
6.3ft |
4.7ft |
3.1ft |
|
2 AWG |
29.8ft |
14.9ft |
9.9ft |
7.4ft |
4.9ft |
|
1 AWG |
37.7ft |
18.9ft |
12.6ft |
9.4ft |
6.3ft |
|
1/0 AWG |
47.5ft |
23.8ft |
15.9ft |
11.9ft |
7.9ft |
|
2/0 AWG |
60ft |
30ft |
20ft |
15ft |
10ft |
|
3/0 AWG |
75.6ft |
37.8ft |
25.2ft |
18.9ft |
12.6ft |
Is The Battery Cable Size Too Small? Or Too Big?
The voltage drop is the first when the battery cable size is too small. This indicates that the wire voltage end is lower than the battery voltage. If there is a considerable voltage drop, the appliance will stop working. The voltage drop can be calculated using Ohm’s law, V=I*R, where V is the voltage, I is the current, and R is the resistance. If there is an increase in the current and resistance, the voltage drop increases. Resistance depends on the wire's length and thickness; hence, under-sizing your battery cable might create an excessive voltage drop.
Another area for improvement with a small battery cable size is overheating and wire melting. Heat is generated when current is passed through the wire, and more resistance in the wire causes overheating. If the battery cable is too small, the wire gets hot, starts melting, and can even cause fire.
If the battery cable size is big, cost is the primary consideration, as thicker wires are expensive. Unless you are running a battery cable of a few feet, there will be no additional cost. As the wire gauge increases, the weight of the battery cable increases. It is challenging to work with thicker cables, especially while bending and operating them in vehicles. However, with more portable and compact solar generators options like the Jackery Solar Generator, you need not worry about cable sizing while using solar energy. This is because the solar generator bundle includes all the necessary cables and connectors.
Jackery Solar Generators Explained
Jackery stands as a pioneer in the field of sustainability by selling around four million units of solar generators, portable power stations, and solar panels. The Jackery Solar Generator is an essential home backup solution combining the Jackery Portable Power Station and Jackery SolarSaga Solar Panels. When the solar panels are placed outside on a bright sunny day, the cells in the solar panels trap sun energy and convert it into electrical energy. This electric energy is stored in a portable power station with a built-in inverter that converts direct current (DC) into alternating current (AC). The Jackery Solar Generators provide solar energy to charge your devices and keep them powered up during off-grid living, blackouts, or outdoor adventures.
Jackery Solar Generator 2000 Plus
The Jackery Solar Generator 2000 Plus supports multiple cable types to charge devices in various locations and situations. Its expandable capacity stores emergency backup power for power outages or unforeseen power cuts. It features a foldable handle, pull rod, and double wheels so you can easily roll the solar generator anywhere you go. With its massive capacity and expandability options, you can rest assured that appliances will stay on, even when the grid fails to supply electricity.
Appliance Working Hours
- Portable Air Conditioner (1150W): 1.4H
- Kettle (850W): 1.9H
- Hand drill (400W): 4.0H
- Refrigerator (300W): 5.3H
- Coffee Maker (800W): 2.0H
Who Should Buy This
If you want an expandable solar generator that can grow with your needs and can help you keep most appliances powered during outages, the Jackery Solar Generator 2000 Plus is a reliable choice.
Customer Review
Amazing. It was expensive, but I did appreciate the coupon. I went off the grid with it, and we love it. We live in a camper and power up everything for at least two days without charging but using everything, so I'm thrilled that we got it. We have a small jackery that we relied on, but now we have no problem with power.
- Marcin Powichrowski
Jackery Solar Generator HomePower 3000
The Jackery Solar Generator HomePower 3000 is an advanced, essential home backup solution that provides reliable power to refrigerators, lights, fans, and more. It's the world's lightest and smallest 3kWh LFP solar generator. With the dual-sided handles, you can easily move it from one room to another wherever power is required. It can also connect to the home's electricity panel via the Jackery Manual Transfer Switch. Whenever the power goes out, the solar generator kicks in to keep essential circuits powered within 20 milliseconds.
Appliances Running Time
- Portable Air Conditioner (1150W): 2.2H
- Kettle (850W): 3.0H
- Hand drill (400W): 6.2H
- Refrigerator (300W): 8.1H
- Coffee Maker (800W): 3.2H
Who Should Buy This
If you want an essential home backup solution that can run core appliances during short outages, you can consider going ahead with the Jackery Solar Generator HomePower 3000.
Customer Review
So far, everything is good. I lost power the first night (lightning strike), not long after I got it charged up. I used it to run an AC window unit, two lights, TV, and computer for more than 1.5hr using 2%of charge. I think that is good to me anyway.
— Kenneth Clark.
Jackery Solar Generator HomePower 3600 Plus
The Jackery Solar Generator HomePower 3600 Plus is an expandable, powerful, and essential home backup solution that can provide up to 14 days of fridge backup. It has a luggage-style design with wheels and a telescoping handle, which makes transportation easier. With up to five Jackery Battery Pack HomePower 3600, you can expand the battery capacity up to 21kWh and enjoy uninterrupted power during long-term outages. It is also compatible with the Jackery Manual Transfer Switch and allows you to switch to backup power in just 10 milliseconds.
Appliances Running Time
- Portable Air Conditioner (1150W): 2.6H
- Kettle (850W): 3.5H
- Hand drill (400W): 7.2H
- Refrigerator (300W): 9.5H
- Coffee Maker (800W): 3.7H
Who Should Buy This
If you want a powerful home battery backup that can run essential appliances with the ability to expand as the power needs grow, the Jackery Solar Generator HomePower 3600 Plus has got your back.
Customer Review
Very easy to set up, solar charge, great support! Going to buy more batteries!
— Mike Palmer.
Common Questions About Battery Cable Size Chart
What size of solar generator do I need?
The right size of solar generator depends on how many appliances you use and how long you use them. If you are using Jackery Solar Generators to power the appliances, the working hours can be calculated by using the Running Time Calculator available on the product page. Let's say you are powering a refrigerator (300W), light (10W), and a small fan (50W) with the help of the Jackery HomePower 3600 Plus. Go to the product page and scroll to find the Running Time Calculator. In this case, the Jackery HomePower 3600 Plus will run these appliances (360W) for 7.7 hours.
How do I figure out how many amps my RV will be using?
To calculate the amps of your RV, you can divide the wattage consumption by the voltage used.
How do I know what size battery cable I need?
You can use a battery size cable chart to determine the size of the battery you will need. You must also know your DC ampere requirement.
What gauge wire to use for a 12V battery?
For a 12-volt system voltage, you can use a 4-gauge wire with a 100-150 ampere rating.
What does AWG mean for battery cables?
AWG stands for American Wire Gauge and is the standard measure for the thickness of a cable.
Conclusion
A battery cable size chart helps you to choose the right size and thickness of the battery with rated current and voltage for your appliances. Selecting the suitable battery cable is essential to prevent voltage drop or overheating of the appliance. An undersized or oversized battery cable can cause several issues to your devices by controlling the electronic system to function correctly. Jackery Solar Generators are compatible with Jackery cables, which prevents overheating or voltage drop by relying on renewable energy.
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