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Main

Wire Size Calculation


This spreadsheet has 3 sections. The first section uses the data as determined by the power spreadsheet.
This will then calculate the resistance and the voltage drop. The main reason we calculate all this stuff
And it's usually much colder that that around here that all winter. The second section is to make the same
Calculation, but by plugging in the values yourself. The third section is a much simplified version to help
calculate wiring for non PV applications. The places you enter data are purple.
Array Data
Open Circuit Voltage
43.1
Short Circuit current of panel
5.46
Cold Weather factor (-40F)
1.25
True Amperage per panel
6.83
Number of panels in series
2
Number of parallel strings
6
Series Per Wire Run
4
Total Array Amperage
51.19
Max Array Voltage
107.75
Max Wire Run Amperage
34.1266667
Max Wire Run Voltage
71.8333333
Max Wire Ampacity
42.5866667
AWG Wire Gauge
2
Distance
135
Voltage
48
Temperature
90
Temp Factor for Copper
0.0032
Temp Change Factor
1.0485
Resistance From NEC Table 8
#N/A
Voltage Loss
#N/A
Voltage Drop
#N/A

Non PV Wiring
Amperage
Wire Ampacity
AWG Wire Gauge
Distance
Voltage
Temperature
Temp Factor for Copper
Temp Change Factor
Resistance From NEC Table 8
Voltage Loss
Voltage Drop

20
31.2
8
10
24
120
0.0032
1.1454
#N/A
#N/A
#N/A

Notes:
Page 1

#N/A

#N/A

Standalone Calculation
Open Circuit Voltage
Short Circuit current of panel
Cold Weather factor (-40F)
True Amperage per panel
Number of panels in series
Number of parallel strings
Series Per Wire Run
Total Array Amperage
Max Array Voltage
Max Wire Run Amperage
Max Wire Run Voltage
Max Wire Ampacity
AWG Wire Gauge
Distance
Voltage
Temperature
Temp Factor for Copper
Temp Change Factor
Resistance From NEC Table 8
Voltage Loss
Voltage Drop

Main
The formula for adjusting NEC table 8 for temperature is as follows:
R2 = R1 [1 + acu(T2 75F)] where Acu = 0.00323

Page 2

Main

spreadsheet.

ake the same

Open Circuit Voltage


Short Circuit current of panel
Cold Weather factor (-40F)
True Amperage per panel
Number of panels in series
Number of parallel strings
Series Per Wire Run
Total Array Amperage
Max Array Voltage
Max Wire Run Amperage
Max Wire Run Voltage
Max Wire Ampacity
AWG Wire Gauge

Temp Factor for Copper


Temp Change Factor
Resistance From NEC Table 8

43.1
5.46
1.25
6.825
2
6
6
51.1875
107.75
51.1875
107.75
63.882
1/0
130
48
50
0.0032
0.9193
0.11215
1.86271
3.88%

OK

Page 3

Main

Page 4

Comments
I11:

Enter the max open circuit voltage of the panel.

I12:

Enter the short circuit current of the panel.

I15:

Enter the number of panels in a series string.

I16:

Enter the number of parallel strings.

D17:

Enter the number of parallel strings for each wire run.

I17:

Enter the number of parallel strings for each wire run.

D23:

Enter the AWG wire gauge you wish to use.

I23:

Enter the AWG wire gauge you wish to use.

D24:

Enter the distance between the PV panel combiner box and the charge controller.

I24:

Enter the distance between the PV panel combiner box and the charge controller.

D25:

Enter the voltage of the wire run between the PV panels and the charge controller.

I25:

Enter the voltage of the wire run between the PV panels and the charge controller.

D26:

Enter the lowest or highest Operating temperature. This effects the resistance.

I26:

Enter the lowest or highest Operating temperature. This effects the resistance.

D37:

Enter the AWG wire gauge you wish to use.

D38:

Enter the distance between the PV panel combiner box and the charge controller.

D39:

Enter the voltage of the wire run between the PV panels and the charge controller.

D40:

Enter the lowest or highest Operating temperature. This effects the resistance.

Page 5

VoltDrop

Voltage drop
NEC Table 8
DC Resistance at 167F, 1000 feet, stranded
AWG
18
16
14
12
10
8
6
4
3
2
1
1/0
2/0
3/0
4/0

Conductors
7
7
7
7
7
7
7
7
7
7
19
19
19
19
19

Area Cir. Copper


Copper
Mils
Uncoated
Coated
1620
7.9500
8.4500
2580
4.9900
5.2900
4110
3.1400
3.2600
6530
1.9800
2.0500
10380
1.2400
1.2900
16510
0.7780
0.8090
26240
0.4910
0.5100
41740
0.3080
0.3210
52620
0.2450
0.2540
66360
0.1940
0.2010
83690
0.1540
0.1600
105600
0.1220
0.1270
133100
0.0967
0.1010
167800
0.0766
0.0797
211600
0.0608
0.6080

Circuit Resistance
Battery @ 12VDC
Battery @ 24VDC
Battery @ 48VDC
Battery contacts
Inverter contacts
Breaker
Conductors

0.0015
0.0030
0.0060
0.0016
0.0004
0.0020
0.0024

Drop = Current in Amps x resistance per foot x length


Voltage drop= Amp x ohms

Page 6

0.0085
0.0053
0.0033
0.0021
0.0013
0.0008
0.0005
0.0003
0.0003
0.0002
0.0002
0.0001
0.0001
0.0001
0.0006

VoltDrop

NEC Table 8
DC Resistance at 167F, 1000 feet, solid
AWG
18
16
14
12
10
8

Area Cir. Copper


Copper
Mils
Uncoated
Coated
1620
7.7700
8.0800
2580
4.8900
5.0800
4110
3.0700
3.1900
6530
1.9300
2.0100
10380
1.2100
1.2600
16510
0.7640
0.7860

Correction Factor for Crystalline Panels


High Temp
77
49
31
13
-5

Low Temp
50
32
14
-4
-40

Factor
1.06
1.1
1.13
1.17
1.25

Page 7

0.0081
0.0051
0.0032
0.0020
0.0013
0.0008

NewPanels

New Panels Project


Size
PV Panels
PV Rack

Quantiy

Cost

Total
$6,540.00
$538.00
$7,078.00

165
12 Panels

12
2

$545.00
$269.00

500'
500'
1000'
500'
250'

1
1
2
1
1

$175.00
$30.38
$51.30
$14.70
$31.25

$175.00
$30.38
$102.60
$14.70
$31.25
$322.68

PVC Pipe
90 Elbows
45 Elbows
Male Thread
Access Fitting
Coupling
Locknut

1.5
1.5
1.5
1.5
1.5
1.5
1.5

14
2
3
2
1
1
1

$3.29
$1.99
$1.69
$0.59
$5.94
$0.59
$0.66

$46.06
$3.98
$5.07
$1.18
$5.94
$0.59
$0.66
$63.48

PVC Pipe
90 Elbows
45 Elbows
Male Thread
Access Fitting
Coupling
Locknut

0.75
0.75
0.75
0.75
0.75
0.75
0.75

14
2
3
2
1
1
1

$1.17
$0.75
$0.65
$0.37
$2.99
$0.75
$0.24

$16.38
$1.50
$1.95
$0.74
$2.99
$0.75
$0.24
$24.55

#2 AWG
#10AWG/2
#Cat 5e
#14AWG Speaker
#2 Bare Ground

Colotex Electric

Home Depot

Combiner Box
30A Fuse Block
8A Fuses
Isolated Ground Kit
Equip Ground, 12 lugs
Lugs #6-2/0
NEMA 3R Box (8x12)
Delta Lightening Arrestor

75747
74778
15850
15846
15843

3
5
2
2
2
1
1

$9.82
$4.49
$7.50
$2.03
$3.30
$23.16
$39.00

PV Subtotal
PVC Subtotal
Wire Subtotal
Combiner Box
Total

$29.46
$22.45
$15.00
$4.06
$6.60
$23.16
$39.00
$139.73
$7,078.00
$88.03
$322.68
$24.55
$7,513.26

Page 8

Colotex Electric

NewPanels
Junction Box (6x6x4)

$10.95

Page 9

$10.95

NewPanels

Colotex Electric

Colotex Electric

Page 10

NewPanels

Page 11

Comments
C15:

5 foot sections

C24:

5 foot section

Page 12