Wire Gauge Calculator

Wire gauge, connector, and voltage drop for every circuit in your e-bike build.

Circuit Type

Battery → Controller

Main DC power bus

Phase Wires

Controller → Motor (AC)

Signal Wires

Hall, throttle, brake, display, PAS

Lighting

Headlight, tail light, accessories

Parameters

Voltage (V)

Controller Amps (A)

Wire Run Length (m)

One-way distance — battery to controller or controller to motor

48V × 30A1.4 kW

Insulation

Build Mode

12AWG

Silicone

Minimum

14AWG

Connector

XT60

60A rated

Voltage Drop

0.17V(0.3%)Low

5.0W loss

Anti-spark circuit recommended

At 48V and 30A (1.4kW), controller capacitors will draw a large inrush current when connected. Use an XT90-S (anti-spark), a dedicated precharge switch, or a smart power switch to prevent connector damage.

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