Wire Sizing

Worksheet
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 Copyright © 2013
TheSolarPlanner.com
Energy Management
Service
See Instructions.

Residential Wire Sizing Worksheet Use link below to

(Gauges, Lengths & Voltage get local high
Drop) temperature.

Max. High
Step 1: Size the source
Temperature Solar ABC's
circuit conductors.
(Celsius)

This calculation applies to PV 2% Avg temp

45
or USE-2 wire between the recommended.
array and the
junction/combiner box. Do not Temperature
use this step to size wire for Correction 0.87
microinverters. Factor

Module Default Max High Temp = 45. (You can

Brand/Model # change defaults. Don't leave the box blank.)

Module Isc - short Module Ipm -

Inverter Model
circuit current operating current

Check box if system is positive grounded Worksheet designed for a grid-tied

0
system with one inverter. Use only
Type only in the black Ampacity 90°C rated conductors, minimum
Calculation gauge 12. Conduit is assumed to
outlined boxes
carry wire for this PV system only.
Conductor gauges may be changed
Minimum Wire Gauge for Conductors in later steps.

Step 2: Size PV Output circuit conductors.

This calculation applies to THWN-2 or other

approved wire that's run through conduit
between a junction box/combiner and the
inverter.

Check here if using a combiner box 0

Number of Array Strings Inches btw Check here if no

2
(Default = 2) conduit & roof conduit on roof 0
Conduit
Circuit Isc 0.00 80% Temp Adder 33
Adjustment
Ampacity Temp Correction
Conductors Exiting Box 4 0.00 0.41
Calculation Factor

Minimum Wire Gauge for Conductors Enter Wire Type:

Project Name: Scroll to the right for Page 2…

Residential Wire Sizing Worksheet
See Instructions. Page 2

Scroll right for Page 3.

Type
Step 3: Size Inverter Output only in
conductors.
the black
outlined
Inverter AC Output boxes
Current - Imax

If indoors, estimate highest

Check box if inverter will be indoors. 0 35
Celsius temp. (Default = 35.)

Check box if conduit will

Conduit
carry more than 3 Indoor Temp Correction 0.96
Adjustment
conductors. (Max=6) 0

Check here if using a

Ampacity Calculation 0.00 100% 1
✘
transformerless inverter

Minimum Gauge for Conductors Wire Type

Step 4: Measure wire lengths. An array EGC will be

shorter if grounding
clips are used on the
Source Circuit: (Use feet only.) String 1 2 3 4 modules.

Distance of home run (i.e. from Length for

array far end to junction box) Ground
Wire(EGC)
Distance of near-end run to box if
not connecting by module cable

Check box if home run is

0 When measuring wire runs, be sure to factor in obstacles,
the positive wire wide turns and an extra foot for wiring inside electrical
boxes. Enter one-way travel distances only. No
PV Output Circuit: roundtrips. Do not factor in the length of module leads.

Distance between Distance of EGC (if different from conductors)

junction box/combiner
and inverter Inverter Out Circuit Distance of
inverter
Wire distance between EGC
Calculations: inverter and main panel

Source Positive 0 Neg. 0 EGC 0 All lengths in feet.

PV Output Positive 0 Negative 0 EGC 0

Inverter Out Hot 0 Neutral 0 EGC 0

Residential Wire Sizing Worksheet
See Instructions. Page 3

Step 5: Perform voltage drop calculations. Enter the number of modules in the array(s).

Module
Module Cable Length Module
Operating 48
in inches Count
Volts Vpm

Source Operating Provide length of one cable only. Array

0.0 A 2
Circuit Current (Default is 48.) Strings

Conductor
Length ft Ohms per kft
gauge

Operating Combiner Selected Scroll left for

0.0 A NO
Current Box? in Step 2. Pages 1 & 2.
PV Output
Circuit
Conductor
Length ft Ohms per kft
gauge

AC Circuit wire gauges Type only in the empty or

Maximum 0.0 A were selected in check boxes outlined in
Inverter Current Steps 1-3. black.
Out Circuit
Conductor
Length ft Ohms per kft
gauge

Calculations:
Note: Step 5 is
Inverter optional. It's accepted
Circuit: Source PV Output practice not to allow the
Out
voltage drop to go too
Voltage much higher than 3%,
Drop but the NEC doesn't
regulate this amount.
Circuit Volts 120 V

Percentage

0 0 0
Check box to
Scroll right for
use the next
Overcurrent
beefier wire New size New size New Size
Protection Ampacity
gauge for this
Check and EGC Sizing
circuit.

Conductor You can change gauges

Gauge again in Step 6.

New Voltage
Drop/%
Do not remove these tables.

Ohms per
Voltage Drop Resistance Gauge kft
for Stranded Wire
1 0.154
2 0.194
3 0.245
4 0.308
6 0.491
8 0.778
10 1.24
12 1.98
Wire Sizing Worksheet After completing this page, click on the
Report tab below to view your results.
Step 6: Compare wire gauge ampacities to any overcurrent device
ratings.
Page 4
Note: Overcurrent protection in the PV Source and PV Output circuits may be optional
when you use less than 3 strings. Check the NEC or ask a qualified expert for
guidance.

Overcurrent Is the wire ampacity

Enter O.C. Conductor Derated Wire
Circuit Ampacity equal to or greater
Rating (if any) Gauge Ampacity
Calculation than the O.C. rating?

PV Source 0.0 A Data Missing

PV Output 0.0 A Data Missing

Inverter Out 0.0 A Data Missing

Fill in each box if you plan to use O.C. protection for that
If the last column above
circuit. An O.C. device is rated in amps. Use the size
reads "check wire gauge",
nearest to, but not less than, the Overcurrent Ampacity
the circuit may require a
Calculation. Click the Resources tab below for links to
beefier conductor. However,
O.C. device sizes. NOTE: Per NEC 690.8(B)(1)(c), for
if the O.C. Rating is the next
any O.C. device subject to an ambient temperature more
available size for the Derated
than 40˚C, you must implement the fuse or breaker's
Wire Ampacity value, you
manufacturer temp correction factors when selecting a size.
can stick with the gauge
Once you've selected O.C. devices, enter values in all
that's listed.
three boxes below.

Conductor Enter final conductor gauges after reading the red instructions above.
Gauges PV Source PV Output Inverter Out

Transformerless See
Step 7: Choose a ground wire and gauge for each circui
inverter selected. Step 3
If a transformerless inverter is used, the EGC (ground wire) for each
NEC Table 250.122
circuit must be rated to carry twice the Overcurrent Ampacity Calc.
For a normal inverter: If an O.C. device is used, pick a gauge that
corresponds to the Max Amps in NEC Table 250.122 (e.g. a 30-amp AWG Max Amps
breaker requires Gauge 10 wire). If no O.C. device is used, pick the
same gauge as the conductors, or beefier. For bare copper, the 12 = 20
minimum gauge is usually 6.
Click Resources tab or NEC
Tables for help.
PV Source PV Output Inverter Out 10 E 30

Minimum EGC Gauge 10 G 40

Wire Type: 0 0 10 C 60

The most commonly used wire type in the Source circuit is Bare
Copper - AWG 6. PV and Inverter Output wire types were picked in 8 = 100
Steps 2-3.
Do not remove these tables.

Free Air Conductor Ampacities for PV

Wire, USE-2 and THWN-2 Copper at 30
degrees Celsius

Gauge Ampacity Ampacity Gauge

1 220 40 12
2 190 55 10
3 165 80 8
4 140 105 6
6 105 140 4
8 80 165 3
10 55 190 2
12 40 220 1

In Conduit Conductor Ampacities for

PV Wire, USE-2 and THWN-2 Copper at
30 degrees Celsius

Gauge Ampacity Ampacity Gauge

1 150 30 12
2 130 40 10
3 110 55 8
4 95 75 6
6 75 95 4
8 55 110 3
10 40 130 2
12 30 150 1
 Copyright © 2013 Energy
TheSolarPlanner.com Management
See Instructions. Service
Residential Wire Sizing Report
Worksheet Checklist Calculations Notes Do not fill in any blanks.

Step 1 Data Missing Transformerless inverter selected.

Step 2 Data Missing
Step 3 Data Missing
Step 4 Data Missing Wire lengths must be entered.
Step 5 Data Missing Voltage drop calculation is optional.
Step 6 Data Missing Conductor gauges or O.C. rating must be entered.
Step 7 Data Missing Ground wire, gauges or wire types must be entered.

Array Source Circuit Results Ground Wire (EGC)

Minimum Conductor Gauge
Use PV Minimum Gauge/Type
Conductor Wire Type
Wire
PV Wire or USE-2 only. 0 0 0

Wire Length Pos. ft. Neg. ft. EGC ft.

PV Output Circuit Results

Ground Wire (EGC)
Minimum Conductor Gauge
Conductor Wire Type Minimum Gauge/Type

0 0 0 0

Wire Length Pos. ft. Neg. ft. EGC ft.

Note: PV Output/Inverter Out calculations assume the same conductor type and gauge.

Ask a PV contractor, electrician, or inspector to verify

Inverter Out Circuit Results
your wire sizes and types before buying any material.

Conductor Wire Type Minimum Conductor Gauge Ground Wire Gauge/Type

0 Transformerless = Ungrounded. 0 0 0
Wire Length Hot ft. Neu. ft. EGC ft.

Wire Totals Use the list below when preparing a purchase order.

PV Wire or USE-2 Pos./Neg. feet Gauge 0

0 EGC/Ground feet Gauge 0
0 Pos./Hot ft. Neg./Neutral ft. Gauge 0
Hot Neutral Gauge
0 Ground/EGC 1 ft. Do not use Gauge 0
grounded
Ground/EGC 2 conductors. Gauge

Modules: 0 Inverter: 0
Project Name: 0
Wire Sizing Calculators
Online Resource Links
Raceway/Conduit Fill Calculator
Electrician2.com
Conduit Fill Calculator Vist the TheSolarPlanner.com Worksheets Page for instr
Southwire.com

Wire Size Calculator Search for Inverter Specs

Electrician.com
DC Cable Sizing Calculator AltE Store
Energy Development Cooperative
Voltage Drop Calculator Civic Solar
Electrician.com
Voltage Drop Calculator Wholesale Solar
NoOutage.com
Conductor Properties Chart Search for Module Specs
BuildMyOwnCabin.com
More Calculators AltE Store
Electricians Toolbox
Low/High Temp Data for U.S. Cities Civic Solar
Solar ABCs
Wholesale Solar
Tutorials
Wire Sizing & Voltage Drop Overcurrent Protection Rating
TheSolarPlanner.com
Typical Sizes - DC fuses (+ 240 volts)
Understanding Electrical Devices, Wire & Conduit
1, 4, 6,
in a
8,Home
10, 12,
PV15,
System
20, 30 amps
TheSolarPlanner.com
Electrical Wire Types & Uses Typical Sizes - AC/DC breakers
EHow.com 10, 15, 20, 25, 30, 40, 45, 50, 60, 70,
Transformerless Inverters 80 amps
CivicSolar.com
Wiring Methods and Materials Typical Sizes - Dual-Pole Backfeed
MikeHolt.com Breakers (for Main Service Panel)
Counductor Sizing and Overcurrent
15, 20, 30, 40, 50, 60, 70, 80 amps
Device Ratings
By John Wiles
Search O.C. Device Sizes Onli
Grounding and Bonding PV Systems
HomePower.com General Purpose Fuses and Breakers
NEC Rules for Ungrounded PV Systems Hardwarestore.com
SolarProfessional.com PV Fuses and Breakers
Code-Compliant O.C. Device Sizing Northern Arizona Wind & Sun
Solar Pro Magazine Lowes - Fuses and Breakers
Grounding PV Systems (Note: Not all brands are compatible with
SolarProfessional.com any electrical component. Always check
component specs before purchasing.)
 Table and Chart Info Extracted from 2011 NEC

Maximum Conductor Ampacities per Ambient Temperature Correction

Gauge (run inside conduit) - from NEC Factor for Conductors - from NEC
Table 310.15 (B)(16) (formerly Table 310.15 (B)(2)(a)
310.16)
USE-2, PV Wire, THWN-2
Temp Celsius
Copper 90° Celsius
USE-2, PV Wire, THWN-2
AWG
Copper 90° Celsius In Conduit and Free Air

14 25 10 or less 1.15

12 30 Also applies 11-15 1.12

to these
10 40 wire types: 16-20 1.08
TBS, SA, 21-25 1.04
8 55
SIS, FEP,
Also applies
6 75 FEPB, MI, 26-30 1.00
to these wire
RHH, RHW-
4 95 2, THHN, 31-35 0.96 types: TBS,
SA, SIS,
3 110 THHW, 36-40 0.91
FEP, FEPB,
THW-2,
2 130 XHH, 41-45 0.87 MI, RHH,
RHW-2,
1 150 XHHW, 46-50 0.82 THHN,
XHHW-2,
1/0 170 ZW-2 51-55 0.76 THHW,
THW-2,
2/0 195 56-60 0.71 XHH, XHHW,
61-65 0.65 XHHW-2,
3/0 225
ZW-2
Always pick a gauge whose ampacity 66-70 0.58
(second column) is equal to or exceeds the 71-75 0.50
value you calculate.
76-80 0.41
Maximum Conductor Ampacities per
81-85 0.29
Gauge (in free air) - from NEC Table
310.15 (B)(17) (formerly Table
310.17) To research local temps, visit:
USE-2, PV Wire, THWN-2
AWG
Copper 90° Celsius
Solar ABC's

14 35
Also applies
12 40 to these
wire types:
10 55
TBS, SA,
8 80 SIS, FEP,
FEPB, MI,
6 105
RHH, RHW- Scroll down for more tables…
4 140 2, THHN,
3 165 THHW,
2 190 THW-2,
XHH,
1 220 XHHW,
1/0 260 XHHW-2,
2/0 300 ZW-2
3/0 350
NEC Tables and Charts cont…

Conduit Adjustment Factor for Multiple Ambient Temperature Adder for

Conductors Inside Raceway - from NEC Raceways on or Above Rooftops -
Table 310.15 (B)(3)(a) from NEC Table 310.15 (B)(2)(C)

Number of Distance Between Roof and Celsius

Percentage Divider
Conductors Conduit Temp Adder
Less than 3 100% 0 to 1/2 inch 33
4-6 80% Above 1/2" to 3 1/2" 22
7-9 70% Above 3 1/2" to 12" 17
10-20 50% Above 12" to 36" 14

"Number of Conductors" does not include

Installers use what's called a "lift" to
the ground wire/EGC, which must also be
elevate conduit running across a roof. The
run through the conduit. (Since current
height of the lift will give you the data you
doesn't normally flow through it, the EGC
need to use this table. If you place your
contributes no heat inside the raceway.) In
junction box below the roof, you can skip
addition, the use of a combiner in the PV
this calculation, so long as the conduit
output circuit reduces the number of
doesn't cross the roof.
conductors entering the conduit.

DC Conductor Properties for Voltage AC Conductor Properties for Voltage

Drop Calculation - from NEC Chapter 9 Drop Calculation - from NEC Chapter 9
Table 8 Table 9

stranded or ohms per Effective Impedance per

AWG AWG
solid? kilofoot kilofoot

14 solid 3.07 14 2.7

14 stranded 3.14 12 1.7
12 solid 1.93 10 1.1
12 stranded 1.98 8 0.69
10 solid 1.21 6 0.44
10 stranded 1.24 4 0.29
8 solid 0.764 3 0.23
8 stranded 0.778 2 0.19
6 stranded 0.491 1 0.16
4 stranded 0.308 1/0 0.13
3 stranded 0.245 2/0 0.11
2 stranded 0.194 3/0 0.092
1 stranded 0.154
1/0 stranded 0.122

Scroll down for more tables…

Minimum Equipment Grounding
Conductor (EGC) Size Based on Temperature Conversion
Overcurrent Devices - from NEC Table Formulas: Fahrenheit/Celsius
250.122
Overcurrent Minimum
Device Rating Gauge (AWG)
C = (F - 32) * 5 / 9
(amps) Copper Wire
15 14 Note: Table
does not F = (C * 9 / 5) + 32
20 12
apply when
30 10
using a
40 10
transformer
60 10 less For an inverter 3800 watts or less, your
100 8 inverter breakers will be 15-20 amps on the AC
200 6 side, and the EGC minimum gauge will be
300 4 12. For a 4,000-10,000 watt inverter, your
breakers should be 30-60 amps on the AC
side with an EGC minimum of 10 gauge.
An O.C. device (aka fuse or circuit breaker)
Many AHJ's, meanwhile, insist on Bare
may be located inside the inverter, AC
Copper gauge 6 for the array EGC. (After
Disconnect, DC Disconnect, Combiner Box
the junction box/combiner, you must
and/or the main panel. Normally, for less
switch to something else, since bare
than three array strings, you don't need
copper can't be run inside conduit.)
overcurrent protection on the DC side, but
Transformerless inverters require that all
there are exceptions. This chart is generally
ground wires be rated for twice the largest
used to size breakers in the inverter output
upstream circuit ampacity.
circuit (on the AC side).

Temperature Conversion Table

Celsius F Celsius F Celsius F
0 32 19 66.2 38 100.4
1 33.8 20 68 39 102.2
2 35.6 21 69.8 40 104
3 37.4 22 71.6 41 105.8
4 39.2 23 73.4 42 107.6
5 41 24 75.2 43 109.4
6 42.8 25 77 44 111.2
7 44.6 26 78.8 45 113
8 46.4 27 80.6 46 114.8
9 48.2 28 82.4 47 116.6
10 50 29 84.2 48 118.4
11 51.8 30 86 49 120.2
12 53.6 31 87.8 50 122
13 55.4 32 89.6 51 123.8
14 57.2 33 91.4 52 125.6
15 59 34 93.2 53 127.4
16 60.8 35 95 54 129.2
17 62.6 36 96.8 55 131
18 64.4 37 98.6 56 132.8