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  1. Step 1: Determine the Current Load. The first step in cable sizing is determining the current load. This is calculated by evaluating the total power consumption of the connected devices and dividing it by the system’s voltage. For example, in a 240-volt system with a total load of 4800 watts, the current would be:

  2. American wire gauge size calculator and chart.

  3. Locate the current flow in amps of your circuit along the top of the chart below. Select the correct circuit type. Examples of Non Critical circuit are general lighting, windlasses, bait pumps, general appliances. Examples of Critical circuits are panel main feeders, bilge blowers, electronics, navigation lights.

  4. Electrical Wire Conversion Table. AWG is a standard denoting wire diameter, whereas the metric conductor sizes according to standard IEC 60228 describe a wire in terms of its cross-sectional area, rather than its diameter, because the cross section is directly proportional to its strength, weight, and resistance.

  5. American wire gauge (AWG) is a standardized wire gauge system for the diameters of round, solid, nonferrous, electrically conducting wire. The larger the AWG number or wire guage, the smaller the physical size of the wire. The smallest AWG size is 40 and the largest is 0000 (4/0).

  6. This wire size calculator will calculate the appropriate wire gauge for a circuit based on amps, voltage, distance, and load. This website provides a wire size calculator, voltage drop calculator, wire ampacity charts and more.

  7. The following chart is a guideline of “ampacity”, or copper wire current-carrying capacity following the Handbook of Electronic Tables and Formulas for American Wire Gauge. As you might guess, the rated “ampacities” are just a rule of thumb.

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