LiTime Wire & Terminal Selection Guide | How to Choose the Right One

Modifying your home's electrical system—whether installing new circuits, extending existing ones, or undertaking a complete rewiring—demands careful material selection to ensure both safety and functionality. Critically, the wire's gauge (its physical size) must precisely match the circuit's amperage rating (its energy level). When wires are too small for the amperage they carry, they can dangerously overheat. This accumulation of excess heat is a known risk, potentially leading to melted insulation, damaged conductors, and even devastating electrical fires.

So, how can you ensure your electrical project is both safe and reliable for the long term? It begins with understanding the specific energy requirements. Knowing the power consumption of any new lighting, appliance, or heater is fundamental. If you're rewiring, identifying your home’s current wire type also provides crucial context. With this information, consulting an electrical wire size chart becomes an indispensable step. This ensures your materials are correctly matched, leading to a smooth installation and a secure electrical environment for your home.

Table of Content

Part 1: Introduction to Wire Gauges
Part 2: Wire Material Selection: Copper vs. Aluminum Wire
Part 3: Insulation Material Choice:PVC, Silicone, and Polyethylene (PE)
Part 4: LiTime MPPT & Inverters Wire Gauge Quick Reference[Hot]
Part 5: Terminal Selection Guide

Part 1: Introduction to Wire Gauges

In this part, we will have a full overview of wire gauges.

1.1 What is AWG?

The American Wire Gauge (AWG) is the standard system used in the United States for measuring the diameter of electrical wires. In the AWG system, the number represents the size of the wire. This value is a comprehensive measure of the overall diameter of the wire's conductive core, which may be composed of multiple strands of finer wires twisted together. A larger number indicates a thinner wire, while a smaller number indicates a thicker wire (see diagram below).

awg wire size chart

1.2 Wire Gauge Chart – Selecting Gauge by Current

Chose the wrong gauge? Check if the wire is hot to the touch. If so, power off immediately and replace with a thicker wire!

gauge size chart by current

Applications by Wire Gauge

AWG 12 (3.31mm²): Suitable for 10–20A current loads, ideal for small home energy storage systems.
AWG 10 (5.25mm²): Suitable for 20–30A current loads, suitable for medium homes or small commercial energy storage systems.
AWG 6 (13.3mm²): Suitable for 50A+ current loads, ideal for high-power systems like large residential or commercial energy storage battery-inverter connections.

1.3 A Quick Summary

① Wire gauges exist because different electrical applications require different power levels. Thicker wires can safely carry more current than thinner ones and transmit power more efficiently over long distances. Using undersized wires for high-current applications can cause overheating and potentially lead to fires.

② Wire size also affects voltage drop. Thinner wires (smaller cross-sectional area) and longer lengths increase resistance, leading to greater voltage loss as current flows through them.

③ LiTime batteries and inverters often require high current transmission, with typical loads reaching tens of amps or more. Choosing the correct wire gauge is therefore critical.

Simply put, selecting wires is like choosing water pipes: larger water flow (higher current) needs thicker pipes (thicker wires), and longer distances require even thicker pipes to avoid insufficient water pressure (voltage).

Part 2: Wire Material Selection: Copper vs. Aluminum Wire

Two main contenders of AWG wire have historically been copper and aluminum. Understanding their distinct properties is key to making an informed decision. So, let's break down the copper wire vs. aluminum wire debate.

wire material selection: copper vs. aluminum wire

2.1 Copper Wire: The Gold Standard for Home Wiring?

For decades, copper has been a preferred material for residential electrical wiring, and for good reason.

Superior Conductivity: Copper wire boasts excellent conductivity. This means it offers low electrical resistance, leading to less energy loss as electricity flows through it. This efficiency is a significant plus for any electrical system.
Enhanced Safety Profile: Safety is paramount in electrical installations. Copper is naturally corrosion-resistant, which helps maintain stable and secure connections over time. This stability minimizes risks associated with poor connections, such as overheating.
Cost Consideration: The primary drawback of copper wire is its cost. It is generally a more expensive material, often cited as being about twice the cost of aluminum.

Recommendation: Due to its excellent conductivity and enhanced safety features, copper wire is widely recommended for home use.

2.2 Aluminum Wire: A Closer Look at the Alternative

Aluminum wire gained popularity at certain times, largely due to its lower cost. However, it comes with a different set of characteristics.

Lower Conductivity: Aluminum's conductivity is significantly poorer than copper's. To carry the same amount of electrical current safely, an aluminum wire needs to have a much thicker cross-section – approximately 56% larger than a comparable copper wire.
Safety Concerns: Aluminum wire is more prone to oxidation. This oxidation can lead to loose connections, which in turn can cause overheating and pose a potential fire risk. These concerns have led to more stringent installation requirements and a general move away from aluminum for many residential applications.
Cost Advantage: The main appeal of aluminum wire is its lower cost compared to copper.

Recommendation: Given the conductivity and safety considerations, aluminum wire is not generally recommended unless absolutely necessary, and typically only for temporary projects or specific applications where its properties are appropriately managed by professionals.

2.3 How to Choose?

For most homeowners planning new installations, extensions, or rewiring projects, the evidence points towards copper as the more reliable and safer long-term investment, despite its higher initial cost. While aluminum is cheaper, its inherent properties require careful consideration and often specialized installation techniques to mitigate risks, making it less suitable for general home use. Always consult with a qualified electrician and adhere to local building codes when making decisions about your home's electrical wiring to ensure a safe and efficient system.

Part 3: Insulation Material Choice:PVC, Silicone, and Polyethylene (PE)

While the conductor material (like copper or aluminum) is crucial for carrying electricity, the insulation surrounding the wire is equally vital for safety, performance, and longevity. The choice of insulation material depends heavily on the specific application, environmental conditions, and required properties. Let's explore three common insulation materials: Polyvinyl Chloride (PVC), Silicone, and Polyethylene (PE).

a chart compare PVC, Silicone, and Polyethylene (PE) wiring material

3.1 Polyvinyl Chloride (PVC) Insulation: The Versatile Workhorse

PVC is a widely used insulation material known for its balanced properties and cost-effectiveness.

Operating Temperature: PVC insulated wires typically operate effectively in a temperature range of -4°F to 221°F (-20°C to 105°C).
Flammability: It offers excellent flame resistance, meeting basic fire safety standards, which is a key reason for its widespread adoption.
Mechanical Properties: PVC provides good mechanical strength and wear resistance. It has a flexible hardness, making it durable for various installations.
Chemical Resistance: This material shows moderate chemical resistance, making it suitable for most general-purpose scenarios.
Typical Applications: You'll find PVC insulation used in control wires, general home wiring, and low-voltage industrial cables.
Pros:
- Better heat resistance than standard PE
- Flame resistance
- Mechanical strength
- Low cost
Cons:
- Moderate heat resistance (compared to more specialized materials)

3.2 Silicone Insulation: Flexibility and High-Temperature Performance

Silicone insulation stands out for its exceptional flexibility and ability to withstand a wide range of temperatures.

Operating Temperature: Silicone excels in extreme temperatures, with a general operating range of -76°F to 392°F (-60°C to 200°C).
Flammability: It has a high combustion temperature (approximately ≥392°F/200°C). Importantly, halogen-free types of silicone insulation do not release toxic Hydrogen Chloride (HCl) gas when burning, offering a significant safety advantage in high-temperature environments.
Mechanical Properties: Silicone is soft and bendable, offering excellent flexibility for applications requiring frequent bending or twisting.
Chemical Resistance: It is resistant to low temperatures and ozone. However, it can be weak against certain chemicals, such as oils.
Typical Applications: Common uses include dynamic scenarios like robotics and drones, as well as high-temperature environments such as engine bays and heating equipment.
Pros:
- Wide temperature range
- High flexibility
- Safer in high-temperature environments (especially halogen-free types)
- No toxic HCl release (halogen-free types)
Cons:
- Weak chemical resistance (against certain substances)
- Higher cost

3.3 Polyethylene (PE) Insulation: Lightweight and Cost-Effective

Polyethylene is another common thermoplastic insulation, often favored for its electrical properties and moisture resistance.

Operating Temperature: PE insulation is suitable for temperatures ranging from -40°F to 158°F (-40°C to 70°C).
Flammability: This is a significant concern with PE, as it has poor flammability and can produce harmful combustion products when it burns.
Mechanical Properties: PE is lightweight and flexible, contributing to ease of handling and installation.
Chemical Resistance: It offers good resistance to chemicals and water.
Typical Applications: Frequently used in household appliances.
Pros:
- Excellent electrical insulation
- Easy processing
- Chemical/water resistance
- Low cost
Cons:
- Poor heat resistance
- Low mechanical strength
- Limited weather resistance
- Poor flammability

Part 4: LiTime MPPT & Inverters Wire Gauge Quick Reference

litime accessory awg reference

Visit LiTime MPPT solar charge controller and inverters collections page to complete your solar system!

Part 5: Terminal Selection Guide

Ring terminals are electrical connectors that secure wires to screws or studs, shaped like a ring and attached to wires via crimping or soldering to ensure stable current transmission.

Commonly used terminal selections typically include Ring Terminals OT Type, Ring Terminals SC Type, as well as other crimp terminals with equivalent performance and functionality that can serve as alternatives. The main difference between the two types of ring terminals mentioned lies in their appearance, while their characteristics and performance are the same.

ring terminals ot vs sc type

5.1 Why Terminal Size Matters

Risks of incorrect size:

Loose connections
Overheating
Potential system failures

Benefits of correct size:

Tight fit for low contact resistance
Ensuring safety and conductivity

5.2 How to Choose the Right Ring Terminals

Step 1: Match wire size

Terminal inner diameter must strictly correspond to the wire cross-sectional area (AWG or mm²). For example, 10AWG wire requires a 10AWG-compatible terminal to prevent detachment after crimping.

Step 2: Confirm Battery Terminals size

LiTime Battery Terminals are typically M8. Verify specific product specifications with LiTime customer service (service@litime.com) to avoid mismatched hole sizes.

Installation Tips

After crimping, check for secure terminal-wire connections to prevent overheating or melting from looseness.
Tighten studs firmly but avoid over-tightening to prevent damage to terminals or studs.

From AWG gauges to ring terminals, every parameter choice is a cornerstone of electrical system stability. LiTime recommends prioritizing current requirements and safety standards to maximize system performance for both residential and commercial projects. For customized solutions or technical support, contact our team at service@litime.com.

Wire &Terminal Selection Guide | How to Choose the Right Wire & Terminal

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