User:Rob Kam/sandbox1/Talk:Wire

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AWG choices

These days the size of a wire is given commonly in AWG. The larger the AWG the thinner the wire. The insulation is not included on the gauge size because this does not affect the wire's current handling capability.[1]

Hookup wire

24 AWG is the standard that most use and fits the popular MTA connector.[2][3]

Use 7/0.2 PVC insulated stranded wire for all general audio and low current interconnections. This works well with 2.54mm Molex KK aka KF2510 crimps and housings. To solder a wire direct to the PCB, first strip the insulatio, twist the strands together and tin with solder. This prevents excessively heating the the and solder pad. For higher current connections, such as power cables use 24/0.2 PVC insulated stranded wire. This heavier gauge wire can't be easily be soldered direct to the PCB, use screw terminals or Faston blade terminals instead.[4]

I recommend 22 to 24 AWG stranded hook-up wire for wiring panels to PC boards. All Electronics sells 25' and 100' rolls of nice quality stranded hookup wire. https://musicfromouterspace.com/


24 AWG or 7/0.2mm stranded PVC for normal interconnects within projects. 24 AWG Solid - point to point wiring on perfboard between components 22 AWG stranded - board to panel parts (pots/switches/etc...)

20 AWG stranded - 120/240 AC (mains) power entry 20 AWG stranded - DC power from distribution to individual boards (non-modular) 20 AWG or 16/0.2mm stranded PVC for higher current interconnects.

16-18 AWG stranded - for DC from power supply to distribution board (size depends on length and current needed) For connections that involve higher currents, such as power supply lines or connections to power-hungry components, you may want to use a larger AWG, like 20 AWG or even 18 AWG, to ensure that the wire can handle the current without excessive voltage drop or heating.

24 AWG 7/0.2[5][6]
Slightly too thin for solderless breadboard wire.[7]
One wire from ethernet twisted pair.[8]

20 AWG 16/0.2 Hookup wire for higher current.[6]

18 AWG 24/0.2




Mike Gorman I use 7/0.2 for all of my hookup connections - I even have some ribbon cable that is the same gauge which I have used on some panels. I use 16/0.2 for most power connections that use 0.156 connectors and use 24/0.2 for the connections between bus boards and PSU's - like in my Oakley PSU to Dizzy connections. The only exception to this is that some PCB's, like from Juergen Haible and Yusynth, use 0.1" connections for power, for these PCB's I normally make an adaptor cable from 0.1" to 0.156 " using 7/0.2 wire. I also use 0.156" crimps which are designed for smaller gauge wire that I get from Farnell (22 to 28 AWG size from memory).

7/0.2mm or similar is the default general-purpose hookup wire, and the size you should have several colours of 7/0.1 is good for lightweight or higher density. 16/0.2 or 24/0.2 for higher power

Single-core 0.25mm kynar/tefzel wire-wrap wire for PCB patching and high density layouts on perfboard. http://www.eevblog.com/forum/chat/general-purpose-hookup-wire/

For general purpose low-power electronics work 22 AWG wire is light, flexible, doesn't take up much space and sturdy enough to be reliable. This size will also conduct sufficient current without problems. High-power applications will require a heavier gauge wire, e.g. between 20 and 16 AWG.[1]

For low-power signal connections, such as those used for control signals or low-level audio signals, a smaller AWG like 22 AWG or 24 AWG may be sufficient. These wires are flexible and can be easily routed on a PCB and inside an enclosure.

Stranded wire is more flexible than solid wire of the same total cross-sectional area. Stranded wire is used when higher resistance to metal fatigue is required. https://en.wikipedia.org/wiki/Wire

For normal interconnects within projects, normally 7/0.2mm stranded PVC for in-cabinet work and 30AWG solid core (wire-wrap wire) for non flexing application on PCBs and proto boards. For higher current, 16/0.2mm. For inernal wiring stuff you don't need extra flexible - in fact it becomes a positive liability because it won't stay where it's put.

38 SWG (0.15mm) single core for prototyping with a wiring pen / magnet wire

33 SWG, 0.25mm uninsulated wire for prototyping ground connections

30AWG single core for non flexing application on PCBs and proto boards.

24 AWG or 7/0.2mm stranded PVC for normal interconnects within projects. 24 AWG Solid - point to point wiring on perfboard between components Wires from ethernet cables are single core 24 AWG

22 AWG stranded - board to panel parts (pots/switches/etc...) 22 AWG single core for solderless breadboard. 22AWG standard wires (to solder potis to pcb for instance). http://uk.mouser.com/ProductDetail/Belden-Wire-Cable/9983-005100/?qs=sGAEpiMZZMtW9UaYX5J1tEcidJtDtRxOXo1lbGje7Ck%3d

20 AWG stranded - 120/240 AC (mains) power entry 20 AWG stranded - DC power from distribution to individual boards (non-modular) 20 AWG or 16/0.2mm stranded PVC for higher current interconnects.

16-18 AWG stranded - for DC from power supply to distribution board (size depends on length and current needed)

Breadboarding

When working with a solderless breadboard use 22 gauge wire single core, and 3/32" heat shrink tubing Wire size acceptability: 0.3 to 0.8mm / 0.288 to 0.841mm (29 to 20 AWG or 20 to 30 SWG).

When working with a breadboard use 22 gauge wire single core, and 3/32" heat shrink tubing

AWG22 or AWG24 generally work well. i personally prefer AWG24. Anything bigger than AWG22 can mangle the breadboard connector (I've had to unmangle some). Anything smaller than AWG24 may not connect reliably. When you cut the wires, cut on an angle, not straight across the wire. This gives you a needle point on one side, and makes insertion easier. (Hypodermic needles are constructed this way for precisely this reason.) https://electronics.stackexchange.com/questions/31675/what-gauge-of-single-strand-wire-works-well-with-breadboards What gauge of single strand wire works well with breadboards?

22 AWG 1/0.6Single core, ideal for solderless breadboard wire.[7] 1/4W resistor lead.[8]

Wire wrap

Wire wrapping wire is usually 30 AWG, for use in very low power and compact circuits.[1]

Types of insulation

PVC silicone https://electronics.stackexchange.com/questions/1039/source-for-flexible-stranded-wire/1114#1114 teflon

Some wire-wrapping wire use a special insulation that vapourises when heated allowing solder joints to be made [9]

Conductor

Single core vs. stranded

Wire is available either solid and stranded. Solid wire keeps the shape it's bent to but is not as flexible and will break sooner if bent too often than stranded wire of a similar gauge.[1]

As to flexibility: Solid wire is the least flexible and will break from repeated flexing very quickly. the higher the stranding for the same AWG the more flexible and longer flex life. As example 22 AWG 7/30 (7 strands of 30) is the coarsest. 19/35 is common but for high repetition flexibility 168/44 might be used. Insulation affects flexibility also with silicone or rubber being the most flexible and silicone also having a high heat tolerance. That is why quality probe leads are very high stranding silicone insulated. hookup wire does not need high strand count because it is intended for infrequent flexing (assembly/repair only). [10]

There are two basic kinds of wire, solid and stranded. Solid wire keeps the shape to which it's bent but isn't as flexible and will break sooner if bent too often than stranded wire of a similar gauge. With stranded wire individual strands can easily break off.[1]

hookup wire
ribbon cable
solid - breadboard
enamelled wire is used to make coils
wire wrap wire
magnet wire
tinned copper wire for links

Screened

Crosstalk Screened Cables screen is usually connected to zero volts or ground and helps to minimise interference Avoid running power supply cables and signal leads within the same loom. Wires and wherefores by Christopher Roper, Maplin-Electronics, Dec 1982, pp. 42-43

Coax you need a supple thin wire with braided shield and stranded center conductor. Something similar to RG174/U w/braided shield and stranded center conductor 2.5mm outer diameter. https://musicfromouterspace.com/

RG174 is the coaxial used for MOTM.[11][12][13][14]

Wire stripping

Insulation can be stripped off with a sharp knife. Take care not to nick the wire, as this will make it mechanically weak and liable to break here. An inexpensive types of wire stripper has shear-type blades with adjustable notches. The wire is placed into the notch, the jaws are closed, cutting the insulation and the wire pulled through stripping off the insulation. The width of the notch varying for different size wires. A more expensive tool combines small knife edges that cut into the insulation with a set of jaws that hold and pull the wire when the handles are squeezed. This type of tool is faster and less likely to damage the wires than the simpler strippers.[1]

Also https://www.modwiggler.com/forum/viewtopic.php?p=3794438

Color coding

monochrome wiring is a pain to follow. [15]

In electronics, red is usually positive power, black is ground, and the rest can be anything. It would be smart to avoid black or red for signals, but otherwise use what you have. Multiple signals with power and ground are often convenient to carry on a ribbon cable. In that case, you end up with whatever colors the cable has. Don't worry about it. However, beware, at least here in the US the standard for the hot lead of electric power is black, neutral is white, and ground is green. If you install house wiring, you should follow this code (or whatever local code there might be in your jurisdiction) but never count on others having done so. https://electronics.stackexchange.com/questions/36317/standard-wire-colors

Color coded wires make troubleshooting easier. There is no official convention but the following lists those widely used.

  • Green, or green and yellow striped, in mains cables: Earth.
  • Red or brown, in mains cables: Live.
  • Black or blue, in mains cables: Neutral.
  • Red with DC circuit: Positive or signal. Right (left is blue, green or white), Ring on TRS jacks
  • Black, with DC circuit: Ground.
  • Orange
  • Yellow +12V on ATX PSU
  • Green
  • Blue -12V on ATX PSU
  • Violet
  • Grey
  • White

[1] page 18 on pdf

Crimp

Stranded wire is made up of many smaller wires and can bend easily. It's usually better not to twist and tin the wire with solder before crimping it. Soldering the strands can make the wire less flexible and more likely to break in situations where it needs to move.

[16]

common wires

Braiding

  1. ^ a b c d e f g Electrical Components: A Complete Reference for Project Builders, by Delton T Horn, Tab Electronics, 1991, ISBN 0830633332
  2. ^ DIY Wires, Mod Wiggler Forum, Oct 2012
  3. ^ Which wire to choose?, Mod Wiggler Forum, Sep 2012
  4. ^ Parts Guide, Oakley Sound Systems, May 2022, p. 16
  5. ^ Music From Outer Space
  6. ^ a b Wires and wherefores by Christopher Roper, Maplin-Electronics, Dec 1982, pp. 42-43
  7. ^ a b Make: More Electronics by Charles Platt, Wiring, p.26
  8. ^ a b What gauge of single strand wire works well with breadboards?, Electrical Engineering Stack Exchange, May 2012
  9. ^ Electronic components: A complete reference for project builders, by Delton T Horn, Tab Electronics, 1992, ISBN 0830633332
  10. ^ Wires - A Guide, EEVblog Forum, May 2012
  11. ^ Mouser part numbers for MOTM and Dotcom power cable wires?, Mod Wiggler Forum, Feb 2014
  12. ^ https://modwiggler.com/forum/viewtopic.php?t=69360
  13. ^ https://modwiggler.com/forum/viewtopic.php?t=140920
  14. ^ Recommend cable and plugs for DIY Eurorack patch cords, Aug 2015
  15. ^ Recommendation please, insulated stranded hookup wire, EEVBlog forum, Oct 2022
  16. ^ Working with Wire by Paul Smith and Bboyho, SparkFun Electronics, Feb 2013
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