Choosing the Right AWG Cable Size for Amperage and Understanding Long Cables vs. Chassis Wiring
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First DIY battery I made, I undersized my wiring and things and the connections got warm. Not hot, but warm.
When working with electrical wiring, selecting the correct Wire Gauge (AWG) size is crucial for safe and efficient operation. The thickness of the wire affects how much current (amperage) it can safely carry. Here's a simplified table focusing on the maximum amperage capacities for chassis wiring and power transmission.
| AWG Size | Max Amps (Chassis Wiring) | Max Amps (Power Transmission) |
|---|---|---|
| 0000 | 380 | 302 |
| 000 | 328 | 239 |
| 00 | 283 | 190 |
| 0 | 245 | 150 |
| 1 | 211 | 119 |
| 2 | 181 | 94 |
| 3 | 158 | 75 |
| 4 | 135 | 60 |
| 5 | 118 | 47 |
| 6 | 101 | 37 |
| 7 | 89 | 30 |
| 8 | 73 | 24 |
| 9 | 64 | 19 |
| 10 | 55 | 15 |
| 11 | 47 | 12 |
| 12 | 41 | 9.3 |
| 13 | 35 | 7.4 |
| 14 | 32 | 5.9 |
Chassis Wiring vs. Long Cables
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Chassis Wiring: Chassis wiring refers to short, internal connections within a device. Because the wires are short, they can handle higher amperage without overheating. This allows for smaller gauge wires to be used even at higher amperage.
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Long Cable Runs: Long-distance wiring, such as running power from one location to another, requires consideration of voltage drop. As distance increases, voltage drops due to the resistance of the wire, so thicker (lower AWG) cables are needed to safely carry the current. These cables are typically used in power transmission where distance is a critical factor.
Understanding these factors ensures your electrical system operates efficiently, whether you're wiring a vehicle’s chassis or managing long cable runs in power transmission applications.