Wire size for 20 A over 100 ft on a 48 V system

Smallest wire that works

4 AWGat 2.57% drop

20 A over 100 ft one-way on a 48 V system

Circuit power20 A × 48 V	960W
Conductor length100 ft out and 100 ft back	200ft
Ampacity alone would allow16.5% drop — legal on heat, not acceptable on drop	12 AWG
Power lost in the cable2.57% of what you are sending	24.6W
— Voltage drop by size —
14 AWGnot rated for 20 A — 15 A max	—
12 AWG20 A rated, drop too high	16.5%7.92 V
10 AWG30 A rated, drop too high	10.33%4.96 V
8 AWG50 A rated, drop too high	6.48%3.11 V
6 AWG65 A rated, drop too high	4.09%1.96 V
4 AWG85 A rated	2.57%1.23 V
2 AWG115 A rated	1.62%0.78 V
1/0 AWG150 A rated	1.02%0.49 V
2/0 AWG175 A rated	0.81%0.39 V
4/0 AWG230 A rated	0.51%0.24 V

Current: 20 A
One-way distance: 100 ft
System voltage: 48 V

Ampacity and voltage drop are two different questions

Ampacity asks whether the wire gets hot enough to be dangerous. Voltage drop asks whether enough of the power arrives at the other end. On a low-voltage DC run they almost never give the same answer, and the bigger one wins.

For 20 A over 100 ft at 48 V, ampacity alone would allow 12 AWG. Voltage drop says 4 AWG — 2.57%, or 1.23 V of the 48 V you started with.

Why the distance doubles

Current goes out on one conductor and comes back on the other. The copper in the circuit is 200 ft, not 100 ft. Forgetting the return leg is how people arrive at exactly half the real drop.

Why it matters more than it sounds

960 W leaves the source. Undersized cable does not just waste a few percent — on a solar charge controller it means the battery never sees absorption voltage, never finishes a charge cycle, and sulphates its way to an early death while every meter in the system reads normal.

What is not in the table

Copper at 75 °C. Aluminium conducts about 60% as well — go up two sizes. Conduit fill, ambient temperature above 30 °C and bundled conductors all derate ampacity further.

Notes

Two different answers, and the bigger one wins. 12 AWG carries 20 A without overheating, but it drops 16.5% over this distance. You need 4 AWG — sized by voltage drop, not by heat.
3% is the NEC informational recommendation for a branch circuit, not a hard rule. On a 48 V DC system it is already generous: 1.44 V of the 48 V you started with.
Running at 48 V is doing a lot of work here. The same 960 W at 12 V would draw 80 A and need a far heavier cable.
Figures are copper at 75 °C. Aluminium runs about 60% of copper conductivity — go up two sizes. Conduit fill, ambient temperature above 30 °C and bundling all derate ampacity further, and none of that is in this table.

Nearby sizes

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