Wire size for 25 A over 60 ft on a 48 V system

Smallest wire that works

4 AWGat 1.93% drop

25 A over 60 ft one-way on a 48 V system

Circuit power25 A × 48 V	1,200W
Conductor length60 ft out and 60 ft back	120ft
Ampacity alone would allow7.75% drop — legal on heat, not acceptable on drop	10 AWG
Power lost in the cable1.93% of what you are sending	23.1W
— Voltage drop by size —
14 AWGnot rated for 25 A — 15 A max	—
12 AWGnot rated for 25 A — 20 A max	—
10 AWG30 A rated, drop too high	7.75%3.72 V
8 AWG50 A rated, drop too high	4.86%2.33 V
6 AWG65 A rated, drop too high	3.07%1.47 V
4 AWG85 A rated	1.93%0.92 V
2 AWG115 A rated	1.21%0.58 V
1/0 AWG150 A rated	0.76%0.37 V
2/0 AWG175 A rated	0.6%0.29 V
4/0 AWG230 A rated	0.38%0.18 V

Current: 25 A
One-way distance: 60 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 25 A over 60 ft at 48 V, ampacity alone would allow 10 AWG. Voltage drop says 4 AWG — 1.93%, or 0.92 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 120 ft, not 60 ft. Forgetting the return leg is how people arrive at exactly half the real drop.

Why it matters more than it sounds

1,200 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. 10 AWG carries 25 A without overheating, but it drops 7.75% 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 1,200 W at 12 V would draw 100 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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