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3.0 Installation
DC Wiring
Battery Cables
WARNING: UNDERSIZED
CABLES CAN OVERHEAT
AND MELT, CREATING A
FIRE HAZARD WHEN
SUBJECTED TO HEAVY
(PEAK) LOADS. ALWAYS
USE A PROPERLY SIZED
CABLE AND LENGTH
RATED FOR THE
AMPERAGE OF THE
INVERTER AND BATTERIES.
NOTE: Use only copper cables.
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.
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
increasing efficiency.
n I
v
e
t r
r e
T
y
M
o
d
l e
D
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U
X
5
1
2
E
5
U
X
6
1
2
6
U
X
1
1
1
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1
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1
1
2
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1
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1
5
1
2
1
34
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 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.
Battery cables must have crimped or soldered and crimped copper compression
lugs unless aluminum mechanical lugs are used. Soldered connections alone are
not acceptable. High quality battery cables are available from Xantrex in an
assortment of lengths: 1½ to 10 feet, and in #2/0 AWG or #4/0 AWG sizes. These
cables are color-coded with pressure crimped, sealed ring terminals.
See Table 3-2 below for minimum recommended cable size for batteries.
Table 3-2 provides recommended minimum cable sizes for various cable lengths
and inverter amperage. "Typical DC amps", as shown in Table 3-2, is based on
low-battery voltage with an efficiency of 85%. Be sure to check with any local
regulatory agencies for additional requirements.
p
c i
l a
1
o t
3
F
e
t e
o (
n
- e
A
m
p
s
5
A
#
2
A
W
G
3 (
3
6 .
m
5
A
#
2
A
W
G
3 (
3
6 .
m
2
0
A
#
2
0 /
A
W
G
6 (
7
4 .
m
2
0
A
#
2
0 /
A
W
G
6 (
7
4 .
m
5
0
A
#
4
0 /
A
W
G
1 (
0
7
4 .
Minimum Recommended Battery Cable Size Vs. Length
w
a
) y
3
o t
5
F
e
t e
o (
n
e
w
a
m
2
)
#
2
0 /
A
W
G
6 (
7
4 .
m
m
m
)
#
2
0 /
A
W
G
6 (
7
4 .
m
m
2
m
)
#
2
0 /
A
W
G
6 (
7
4 .
m
m
2
m
2
)
#
2
0 /
A
W
G
6 (
7
4 .
m
m
m
m
)
#
4
0 /
A
W
G
1 (
0
7
4 .
m
m
2
Table 3-2
©2002 Xantrex Technology Inc. All Rights Reserved.
) y
5
o t
1
0
F
e
t e
o (
n
- e
w
a
) y
2
)
#
2
0 /
A
W
G
6 (
7
4 .
m
m
2
)
)
#
2
0 /
A
W
G
6 (
7
4 .
m
m
)
2
2
)
#
4
0 /
A
W
G
1 (
0
7
4 .
m
m
)
2
2
2
)
#
4
0 /
A
W
G
1 (
0
7
4 .
m
m
2
)
)
#
4
0 /
A
W
G
1 (
0
7
4 .
m
m
)
2
2
P/N 975-0026-01-01 Rev A 06/2002
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