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Battery Cable Sizing for Freedom Series Inverter/Chargers


The bigger the battery cables, the better. Undersized cables result in additional stress on the inverter, lower efficiency, reduced surge power, and lower peak output voltage. Using cables that are too small in diameter or too long will degrade the Freedom Series efficiency and may constitute a fire hazard. The following table gives recommended cable sizes for various cable run lengths and inverter voltages.

Warning

Use only appropriately sized copper cable. Loose connections or improper connections may constitute a fire hazard, as resistance caused by too long or too small in diameter cable generates sufficient heat to start a fire, potentially causing personal injury or death.

Minimum Recommended Battery Cable Size (In Free Air)

Freedom 458 and Freedom Marine Minimum Recommended Battery Cable Size vs. Cable Length
Model Cable Length
1 to 3 Feet
Cable Length
3 to 6 Feet
Cable Length
6 to 10 Feet
Freedom 10 No. 2 AWG
(2 gauge)
No. 2 AWG
(2 gauge)
No. 2/0 AWG
(00)
Freedom 15 No. 1/0 AWG
(0)
No. 1/0 AWG
(0)
No. 2/0 AWG
(00)
Freedom 20 No. 2/0 AWG
(00)
No. 2/0 AWG
(00)
No 3/0 AWG
(000)
Freedom 25 No. 2/0 AWG
(00)
No 3/0 AWG
(000)
No 3/0 AWG
(000)
Freedom 30 No 3/0 AWG
(000)
No 3/0 AWG
(000)
No 4/0 AWG
(0000)

The National Electric Code (NEC) requires that the cables be protected by a fuse or breaker rated to match the cables' ampacity at 90 °C.

Battery Cable to Maximum Breaker/Fuse Size
Cable Size
Required
Rating In Conduit Maximum Breaker Size Rating in "Free Air" Maximum Fuse Size
No. 2 AWG 115 Amps DC 125 Amps DC 170 Amps DC 175 Amps DC
No. 1/0 AWG 150 Amps DC 150 Amps DC 230 Amps DC 250 Amps DC
No. 2/0 AWG 175 Amps DC 175 Amps DC 265 Amps DC 300 Amps DC
No. 3/0 AWG 200 Amps DC 200 Amps DC 310 Amps DC 350 Amps DC
No. 4/0 AWG 230 Amps DC 250 Amps DC 360 Amps DC 400 Amps DC
350 MCM 310 Amps DC 350 Amps DC 505 Amps DC 600 Amps DC

The National Electrical Code (NEC) allows rounding up to the next fuse size from the cable rating. For example, a 150-amp cable size rounds up to a 175-amp fuse size.

This document is intended to provide general recommendations for fuse and cable sizing. ALWAYS consult local and national electrical codes for proper fuse and cable size prior to installation.


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