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American Wire Gauge Chart
American Wire Gauge (AWG)
The American Wire Gauge is a standard method of denoting wire diameter, by measuring the diameter of the conductor (bare wire) with the insulation removed. WURTON recommends the following gauge wire be used, depending on the length of wire run (with all bends and routing included in total length), and the maximum amp draw of the system.
The ground lead on the light bar should not be extended (if possible). Always connect ground leads directly to the chassis (frame) of the vehicle. Any other grounding method may result in amp spikes that may damage the light bar, as well as sporadic & undesired operation.
Install relays that are rated properly compared to amp draw of light bar(s). Always install relays as close to the battery as possible.
Fine stranded copper wire is the item of choice (more strands in the wire result in a better, more flexible, cable). The insulation should be approved for automotive applications. This means that the wire is relatively immune to the adverse effects of petroleum products (gas, diesel, oil, brake fluid, radiator coolant, etc.).
Failure to use wiring of adequate gauge may result in irreparable damage to the light bar, melted wires, and may cause a fire. Improper installation is not covered by WURTON Manufacturer Defect Warranty. Failure to adhere to these recommendations and installation procedures can ensure decreased performance, shortened life expectancy of the light bar, as well as possible damage to a vehicle’s electrical system. Following the wiring gauge recommendation above will ensure an acceptable voltage drop of no more than 3% in 12-volt circuits.