Electronic – Is it bad practice to connect wires of vastly different gauges

amperagebatteriescablesgauge

I would like to connect an Anderson plug with 25mm² cable to a 12V AGM battery so that I can easily connect and disconnect different devices which will conduct currents of varying amperage. I may connect 2mm² cable for conducting <500mA, 10mm² cable for charging at 20A or an 800W inverter using 25mm² cable for drawing up to 60A.

Is it bad practice to connect cables of vastly different gauges so long as the thinnest wire can comfortably conduct the magnitude of current required?

Can a wire’s gauge be too low to suitably conduct a very small current or is it a case of the thicker the wire the better the conduction regardless of the magnitude of the current?

Best Answer

Since you are talking about connecting to a lead-acid battery it's pretty clear that there are no high frequency signals involved, so the inductance of the cable (and the skin effect) are not relevant in this case.

For low frequencies, larger diameter cables will provide less resistance to current flow so they are generally preferred. Electrically, it is OK to connect heavier cables to smaller cables. However there is some risk here and the practice may be prohibited by local electrical codes. For example, you connect a cable and plug designed for 30A to another wire that is rated for 15A. You know the limitation of the entire circuit is 15A, but someone else comes along, sees the 30A plug, and tries to draw 25A through the circuit. That would be a fire hazard.