Are you planning to install a Tesla Wall Charger at your home but don’t know how to select and install a Tesla Wall Charger gauge wire?
Whether you’re installing a Tesla Gen 3 Wall Connector or a Tesla Wall Connector Gen 4, choose the wire gauge based on the amperage of your charger. Afterward, follow Tesla’s wiring instructions for the installation.
This comprehensive guide on tesla wall charger wire gauge will actually help you to choose the right gauge wire as well as assist you in installing it correctly. So, stay tuned!
Quick Glance:
- The most common and recommended Tesla wire gauges are 4 AWG, 6 AWG, 8 AWG, and 12 AWG.
- But Tesla recommends using a minimum of 6 AWG copper wires for installing Tesla Home Charging Solutions, like the Wall Connectors.
- According to NEC, you can only have a constant load at 80% of the wire’s amperage rating. This means that if your Wall Connector draws 48 amps, you’ll require at least a 60-amp wire.
Why Is Tesla Wall Charger Wire Gauge Important?
These Chargers are designed to charge Tesla electric vehicles at up to 48 amps faster rate. Due to the high amount of power that they deliver, they require a heavy-duty electrical wiring setup to support this level of power transfer.
The wire gauge determines the charging speed of Tesla vehicles. A thicker electrical wire with a lower gauge can carry more current compared to a thinner wire with a higher gauge.
This means that if you select a larger wire gauge that will result in slower charging times due to its limited capacity to carry electricity.
How Does Wire Gauge Affect Charging Speed and Safety?
- Using the correct wire gauge is essential to prevent excessive heat buildup.
- Since the thicker gauge wires can handle higher currents without overheating your car. It will also allow you to charge your Tesla faster.
- Using a wire gauge that is too small for the Tesla charger’s power requirements can lead your car to experience various issues during charging, such as overheating, and voltage drop.
- Too much current flowing through a thinner wire can cause excessive heat buildup and wire insulation to melt or even the wire to melt.
Types of Tesla Wall Charger Wire Gauge
1. American Wire Gauge (AWG) was introduced in 1857 as the “North American Wire Gauge standard” for round, solid, and single-strand electrically conductive wire.
Based on Tesla’s recommendation, you can use a wire gauge ranging from 12 AWG to 4 AWG for your Wall Connector. However, a 10 AWG wire is sufficient for the ground wire.
Even if you are planning to use the wire on a 60A circuit breaker, a 6 AWG wire will be sufficient for your Tesla Charger.
2. Metric Wire Gauge (SWG) also known as “Standard Wire Gauge” and “British Standard Gauge.”
This is a unit used for denoting wire size. It was originally developed in Britain and is specified in the British Standard BS 3737:1964. Also, available in countries or regions that utilize the metric system. The SWG measures in both inches and millimeters and is often used for sheet metal and wire size marking.
However, Tesla Wall connectors are not compatible with a Metric Wire Gauge or “Standard Wire Gauge” (SWG).
Which Wire Gauge is Best for Tesla Wall Chargers?
The general rule is that the higher the amperage, the thicker the wire is needed as it will be more reliable in loading high-voltage energy flow.
Factors To Consider When Choosing a Wire Gauge:
Charging Power:
Different Tesla models have varying power requirements. Thus, check your Tesla Model’s specifications before choosing a wire gauge.
For example, for a 20-amp charger, a 12-gauge wire is advised, while for a 40-amp charger, an 8-wire gauge is recommended. However, you should use a 4-gauge wire for a 60-amp Tesla Wall Charger.
Copper wire:
Note that Tesla recommends a minimum of 6-gauge (AWG), 90° C rated only copper wire for maximum power output. Thus, make sure to avoid choosing other types of wire.
More Efficiency:
Note that using a thicker wire can result in less heating and more efficiency. Therefore, even though an 8-gauge wire is the minimum requirement for a Tesla Charging Wall Connector, a 6-gauge wire might be a better choice for improved performance.
Distance:
The longer distance between the electrical panel and the charging point requires thicker wires to compensate for voltage drop. Thicker wire will ensure that the charger receives the necessary power to deliver efficient charging.
How To Calculate the Appropriate Wire Gauge for Your Tesla Wall Charger?
If you want to manually calculate the correct Tesla Charger wire size, you will need to determine:
- the current required by your vehicle,
- the distance between the electrical panel and the charger, &
- the allowable voltage drops.
You can use an online wire gauge calculator or consult with a Tesla-licensed electrician.
However, if you don’t want to go through that hassle, follow Tesla’s recommendation:
- Use an 8-gauge wire for a 40-amp charger,
- A 12-gauge wire for a 20-amp charger, and
- A 4-gauge wire for a 60-amp charger.
Common wire gauge options for Tesla Wall Chargers:
- 12-gauge (AWG): Commonly used for Tesla charger installations of up to 30 amps.
- 8-gauge (AWG): It is recommended when the charging distance increases or the power requirements exceed 30 amps (40A).
- 4-gauge (AWG): A 4 AWG wire gauge is advised for chargers operating at 60 to 64 amps.
Related Post: Can I Return Tesla Wall Charger? (Answers and Solutions)
Installation Tesla Wall Charger Wire Gauge: 7 Steps Only
Step_1: Choosing between Wire Entry Options based on your need and preferences:
- Top entry location
- Rear (left or right) entry locations, and
- Bottom entry location
Step_2: Preparing Connector Wirebox
The default conduit size is 3/4-inch (21 mm), but a 1-inch (27 mm) conduit is acceptable when necessary.
Prepare the wire box based on fittings and conduit size:
- For “Top” or “Bottom” entry: You should remove the conduit plug manually.
- For “Rear” entry: Drill with a 1-1/8-inch (29 mm) step bit to match the fittings.
- For 1 inch (27 mm) “Rear” and “Bottom” entry: You should drill with a 1-3/8-inch (35 mm) step bit.
Step_3: Preparing for Mounting the Surface
Select a surface that can endure and support the weight of your Wall Connector, such as Plywood or other flat wall surfaces. Otherwise, locate a wooden support stud with a stud finder.
Place the given cardboard mounting template on the installation surface based on the wire entry choice you’ve chosen.
Then drill two pilot holes (one from the “top” and one from the “bottom” row as shown in the wiring diagram) with a 5/32-inch (4 mm) bit.
Step_4: Prepare and Mounting the Wirebox to the Wall
First, drill two pilot holes into the wirebox with a 1/4-inch (6.5 mm) bit that matches your chosen locations on the cardboard mounting template.
Use the provided 4 mm hex bit and two wood fastener screws to secure the wirebox to the mounting point.
Step_5: Route the Designated Wire
Connect the wire to the desired entry points and through the service loop channel on the right side of the wirebox as seen in the Tesla charger wiring diagram below:
Use proper cable glands, bushings, or fittings to keep the wiring in place and protect it from water and dirt.
Step_6: Strip and Land Wiring
Strip the insulation from the wires by 1/2 inch (13 mm), route them via the service channel, and anchor each wire in its proper termination block.
Use the provided zip tie to secure the wiring in the service channel. Torque the terminal screws to 50 lbf. in. (5.6 Nm) with a torque driver and the provided 4 mm hex bit.
Step_7: Attach and Energize Your Wall Connector
Finally, push the Charger’s main unit into the wirebox. Then fasten the main Wall Connector unit to the wirebox using the provided bolts and 4 mm hex bit.
During this process, apply firm pressure to the Connector’s faceplate to compress the internal seal.
Next, turn on the upstream circuit breaker to energize the Charger and you will see the LED on your Charger is illuminating.
6 Tips For Installing Tesla Wall Charger Wire Gauge
Related Post: Can Tesla Wall Connector Charge Other Cars?
Frequently Asked Questions [FAQs]
What gauge wire to use for Tesla Wall Charger?
Tesla recommends using minimum #6 American Wire Gauge 90° C rated copper wire for the Wall Charger installation.
Can I use a wire gauge that is too large for my Tesla Wall Charger?
It is not advisable to choose a wire gauge that is too large for your Tesla Wall Charger since this can result in a waste of money and resources.
What happens if I use the wrong wire gauge for my Tesla Wall Charger?
Based on the Tesla Gen 3 Wall Connector Manual, using the wrong wire gauge can potentially damage the vehicle’s battery, components, and/or the Wall Connector itself.
Can I upgrade my Tesla Wall Charger wire gauge?
Yes, you can upgrade the wire gauge for your Tesla Wall Charger.
