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Wire Size

 

Take a look at this wire. It is what we call Stranded wire. It has multiple strands of copper wire, twisted together.  This is the type of wire you need to be using with DC voltage.

 

Selecting the correct wire size and type is important for many reasons:

  1. Safety - If the wire is too small for the load, the wire can overheat or burn; causing damage and possible fire.

  2. Voltage Drop - The larger the wire, the less resistance, which means less voltage is dropped along the length of the wire. As the wire gets longer, more voltage is dropped.

  3. The wire that your HHO Generator is attached to, should be able to support at least 2 times the maximum amperage you plan on using (if possible), so that the wire does not become a fuse (get hot and melt). Wire that supports more than 2 times the maximum current flow is often used to reduce voltage loss due to the wire (caused by the wire resistance).

  4. In careful engineering, you should take into account the voltage drop, insulation temperature limit, thickness, thermal conductivity, air convection, temperature, and even frequency.

 
 
 

Wire Gauge Table

 

 

Minimum Stranded Wire Size - Length in Feet

Amps Watts 2' 4' 6' 8' 10' 12' 14' 16' 20' 24' 28' 33' 42' 50'
10 120 16 16 16 14 14 14 12 12 10 10 10 8 8 4
15 180 16 16 14 14 14 12 10 10 8 8 8 4 4 4
20 240 16 14 14 12 12 10 10 8 8 8 4 4 4 4
25 300 14 14 12 10 10 10 8 8 4 4 4 4 4 0
30 360 14 14 12 10 10 8 8 8 4 4 4 4 0 0
40 480 14 12 10 8 8 8 4 4 4 4 4 0 0 0
50 600 12 12 10 8 4 4 4 4 4 4 0 0 0 0
60 720 12 10 8 8 4 4 4 4 4 0 0 0 0 0
70 840 12 10 8 4 4 4 4 4 0 0 0 0 0 0x2
80 960 12 8 8 4 4 4 4 0 0 0 0 0 0x2 0x2
90 1080 12 8 4 4 4 4 0 0 0 0 0 0 0x2 0x2
100 1200 10 8 4 4 4 4 0 0 0 0 0 0x2 0x2  
120 1440 10 8 4 4 4 0 0 0 0 0 0x2 0x2    
140 1680 10 4 4 4 0 0 0 0 0 0x2 0x2      
160 1920 8 4 4 0 0 0 0 0 0x2 0x2 0x2      
180 2160 8 4 4 0 0 0 0 0 0x2 0x2        
200 2400 8 4 4 0 0 0 0 0x2 0x2 0x2        
250 3000 4 4 0 0 0 0 0x2 0x2 0x2          

Note: 0x2 = use two 0 gauge wires (double up the wire)

Remember, the footage is double the distance you measure if you are running a separate ground wire, and not using the chassis ground. That is because electrical current is flowing from the battery negative to the cell, and from the cell positive to the battery positive. Most people do not think about this factor. It is a common mistake. So, if you are using the correct gauge wire - based on the length of the wire, and the wire is getting hot, chances are you did not calculate the return trip to the battery.

 

 

 

Zip-Wire - Red and Black

Red/Black Zip Cord is a low voltage DC power cable. Also called zip wire and bonded wire, the cables pull apart for quick separation. Easy to identify polarity for DC applications. 

  Available at Bulk Wire.com

  Available at Power Werx.com


 

35 Feet, Automotive Hookup Wire, 10 gauge

  Available from Radio Shack.com

35 Feet, Automotive Hookup Wire, 10 gauge

  Available from Radio Shack.com

   

 

Page Last Edited - 01/30/2016

 

    Copyright 2003   All rights reserved.   Revised: 01/29/16.                                             Web Author, daddyo44907
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