Selecting the Right AWG Wire for Smarter, Safer Industrial Performance

In today's world of advanced manufacturing and automation, every detail matters, especially when it comes to wiring. Choosing the right wire gauge might seem like a small decision, but it has a big impact on how safely and efficiently your systems run. The correct wire gauge ensures that your equipment receives the proper amount of power without overheating or energy loss. It not only keeps operations reliable and safe but also helps prevent unexpected downtime and costly repairs. Understanding how wire gauge affects performance can help you make smarter choices that keep your systems running smoothly for the long term.

Why AWG Matters

AWG, American Wire Gauge, represents the standard U.S. measurement for wire diameter which extends from 0000 (the largest size) to 40 (the smallest size). Think of wire gauge like the width of a pipe: the thinner it is, the less current it can safely carry. 10 AWG wires represent the suitable option for many motor and heavy-duty equipment power transmission because they carry high current while reducing electrical resistance. On the other hand, 22-24 AWG wires serve as an ideal choice for sensors and data lines and control signals because they offer lightweight flexibility and cost-effectiveness. The selection of an inappropriately small wire gauge will likely result in overheating and voltage loss; over sizing, although safer, adds unnecessary costs. Both situations that most manufacturers would like to avoid. AWG selection requires careful evaluation of several important factors.

Key Considerations in AWG Selection

Power Requirements

The National Electrical Code (NEC) establishes ampacity ratings which represent the highest safe current levels that wires can carry. 12 AWG copper wires can handle up to 20 amps according to NEC Table 310.16 which makes them appropriate for motor applications, but AWG 18 wires are commonly selected for control circuits that carry low currents, typically well below 7 amps, in order to comply with safety codes and minimize the risk of overheating in industrial environments. Always consult NEC or local code tables when choosing wire size for your specific application.

Distance and Voltage Drop

Longer cables create additional resistance, which reduces system performance. NEC Article 210.19(A)(1) stipulates that the maximum voltage drop should be no greater than 3% for all branch circuits. Therefore, to meet both NEC voltage drop requirements at 3% and peak system performance, the NEC requires 120V systems to use conductors with a 14 AWG rating or thicker (12 AWG or 10 AWG) when they extend beyond 50 feet.

Flexibility and Installation

The 22-28 AWG range consists of highly flexible wires for use in robotics and other dynamic systems. Thicker gauges, such as 10-20 AWG, are ideal for stationary equipment as they offer greater durability and current-carrying capacity, making them perfect for motors, actuators, and control panels.
AWG by Application

• Power Equipment (Motors, Actuators, Assembly Lines): 10-14 AWG
• Control & Signaling (PLCs, Relays, Panels): 16-20 AWG
• Sensors & Data (Low-Voltage Sensors, Ethernet Cabling): 22-28 AWG

The wiring specifications follow NEC requirements together with UL/CSA guidelines and ANSI/TIA cabling standards to provide safe and efficient wiring for industrial use.

Powering Industrial Connections

Selecting the correct wire directly affects the continuous operational reliability of your systems. Mencom offers industrial wiring solutions to help manufacturers build factory equipment that complies with regulations and could help to reduce operational risks and system downtime in harsh environments. The company supplies industrial wires and connectors in common AWG sizes ranging from 10 to 24.

Please visit www.mencom.com for more details.

5750 McEver Rd.
Oakwood GA 30566
USA

Founded in 1987, Mencom Corporation provides high-quality, cost-effective solutions that meet industrial electrical connector requirements. Our highly trained staff of experts utilize decades of electrical and electronic industry-related experience to develop the highest quality products available. In addition, this vast expertise allows us to assist OEM customers in selecting the best products to meet their unique connection requirements. This ensures our customers receive the most cost-effective solution possible, plus one that requires minimal installation time, reducing the customer's total installed costs. Mencom is also the North American Master Distributor for ILME rectangular connectors. Mencom's headquarters and warehouse facilities are located in Oakwood, Ga., just north of Atlanta. To speak with one of Mencom's Territory Account managers, simply Contact Us today.

This release was published on openPR.