13
2.0 INSTALLATION
©2000 Xantrex Technology Inc.
Wiring
DC Wiring (Batteries)
Battery Cable Sizing
Proper cable sizing (diameter and length) is critical to the safe and efficient operation of an
inverter system. Larger diameter cables (smaller AWG number) have less voltage drop and are,
therefore, more efficient when transferring power to and from the batteries. If a cable is undersized
(diameter too small), it could potentially overheat, creating a fire hazard.
Cable length is another important factor. Runs should be kept as short as practical. Longer
cable runs increase resistance, thus lowering the overall efficiency of the system. This is especially
true in lower voltage systems (i.e., 12 VDC) where, depending upon the length of the cable run, it
may be necessary to oversize the diameter of the wire, or parallel (double) the cables.
Always use a properly sized cable and length rated for the amperage of the inverter and
batteries.
WARNING: UNDERSIZED CABLES CAN OVERHEAT AND MELT, CREATING A FIRE HAZARD
WHEN SUBJECTED TO HEAVY (PEAK) LOADS.
NOTE: If the system will be operated at the inverters peak power rating exceeding one hour, larger
cables and disconnects MUST be used (see Tables 1 and 2).
NOTE: If the system includes a large battery bank or large DC source (such as a micro-hydroelectric
plant or wind generator), increasing the size of the cables and disconnects will greatly reduce the
number of nuisance outages associated with breaker tripping and open fuses.
Table 1 provides recommended minimum cable sizes for various cable lengths and inverter
amperages. These recommendations may not meet all local or NEC requirements.
NOTE: Use only copper cables.
NOTE: Run the positive and negative battery cables as close to each other as possible by taping
them together. This reduces the effects of inductance and produces a better waveform thus
increasing efficiency.
Inverter
Model
Typical
Amperage
1 to 3 Feet (one-way)
3 to 5 Feet (one-way)
5 to 10 Feet (one-way)
DR1512
150 A
#2/0 AWG (67.4 mm
2
)
#2/0 AWG (67.4 mm
2
)
#4/0 AWG (107 mm
2
)
DR2412
240 A
#4/0 AWG (107 mm
2
)
#4/0 AWG (107 mm
2
)
NOT RECOMMENDED
DR1524
75 A
#2/0 AWG (67.4 mm
2
)
#2/0 AWG (67.4 mm
2
)
#4/0 AWG (107 mm
2
)
DR2424
120 A
#2/0 AWG (67.4 mm
2
)
#4/0 AWG (107 mm
2
)
#4/0 AWG (107 mm
2
)
DR3624
180 A
#4/0 AWG (107 mm
2
)
#4/0 AWG (107 mm
2
)
#4/0 AWG (107 mm
2
)
975-0012-004
Table 1
Minimum Recommended Battery Cable Size VS. Length
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