Wire size for 80 A over 250 ft on a 12 V system
| Circuit power80 A × 12 V | 960W |
|---|---|
| Conductor length250 ft out and 250 ft back | 500ft |
| Ampacity alone would allow102.67% drop — legal on heat, not acceptable on drop | 4 AWG |
| — Voltage drop by size — | |
| 14 AWGnot rated for 80 A — 15 A max | — |
| 12 AWGnot rated for 80 A — 20 A max | — |
| 10 AWGnot rated for 80 A — 30 A max | — |
| 8 AWGnot rated for 80 A — 50 A max | — |
| 6 AWGnot rated for 80 A — 65 A max | — |
| 4 AWG85 A rated, drop too high | 102.67%12.32 V |
| 2 AWG115 A rated, drop too high | 64.67%7.76 V |
| 1/0 AWG150 A rated, drop too high | 40.67%4.88 V |
| 2/0 AWG175 A rated, drop too high | 32.23%3.87 V |
| 4/0 AWG230 A rated, drop too high | 20.27%2.43 V |
- Current
- 80 A
- One-way distance
- 250 ft
- System voltage
- 12 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 80 A over 250 ft at 12 V, ampacity alone would allow 4 AWG. Voltage drop says larger than 4/0 — %, or V of the 12 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 500 ft, not 250 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
- At this length ampacity and voltage drop point at the same wire, which is unusual. Runs over about 20 ft at low DC voltage are normally decided by drop, not by heat.
- 3% is the NEC informational recommendation for a branch circuit, not a hard rule. On a 12 V DC system it is already generous: 0.36 V of the 12 V you started with.
- 12 V is what makes this expensive. The same 960 W at 24 V halves the current and quarters the loss — the cheapest way out of a big cable bill is almost always a higher system voltage.
- 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
- Wire size for 70 A over 250 ft on a 12 V system
- Wire size for 100 A over 250 ft on a 12 V system
- Wire size for 60 A over 250 ft on a 12 V system
- Wire size for 125 A over 250 ft on a 12 V system
- Wire size for 80 A over 200 ft on a 12 V system
- Wire size for 80 A over 300 ft on a 12 V system
- Wire size for 80 A over 150 ft on a 12 V system
- Wire size for 80 A over 250 ft on a 24 V system
- Wire size for 80 A over 250 ft on a 48 V system
Read more
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- Converting kW to Panels, and the Three Ratings That Get ConfusedThree different numbers on a solar quote are all measured in kilowatts and none of them mean the same thing. Knowing which is which makes quotes comparable.