Here's my challenge to all of you that want to design for 1% or 1.5% voltage drop all the time:
Take a 50-ft circuit carrying 40 amps at 12 volts, going to a C40 charge controller, select your wire size for 1% or 1.5% loss. You know that's not a practical solution.  I know that it makes more sense to replace the charge controller and run the PV circuit at a higher voltage.

At % loss did it become impractical?  Ray's answer and my answer is "when there is a cheaper alternative -- lower cost per watt out or lower cost per kWh over the project life."  And that answer works even when you are considering a 400-kW PV array that is 1000 feet away.

Kent Osterberg
Blue Mountain Solar, Inc.

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