Selecting the correct cable: American Wire Gauge (AWG) is a U.S. standard for wire size and commonly referenced for RC cables. The gauge is related to the diameter of the wire. The higher the gauge number, the thinner the wire. Generally speaking lower gauge, larger diameter wire can handle more current. However, the relationship between gauge and carrying capacity isn’t straightforward. It’s influenced by other factors including: voltage drop, insulation, temperature limits, thermal conductivity and air convection. Therefore, as a rule of thumb only, the following chart indicates the max continuous amp rating for silicone cable 20 – 8 AWG. Note that the cable is capable of withstanding short surges of several times these values.
AWG |
Area |
Diameter |
Current |
20 |
0.52mm² |
0.812mm |
up to 11A |
18 |
0.82mm² |
1.02mm |
up to 16A |
16 |
1.31mm² |
1.29mm |
up to 22A |
14 |
2.08mm² |
1.63mm |
up to 32A |
12 |
3.31mm² |
2.05mm |
up to 45A |
10 |
5.26mm² |
2.59mm |
up to 65A |
8 |
8.37mm² |
3.26mm |
up to 95A |
High stranded, silicone wire is best suited for multirotor applications as it’s low resistance, very flexible and has a 200°C rating. Different parts of a multirotor wiring harness require different gauges. It is important to correctly match cable gauge to the current draw to prevent electrical failures but equally to minimise unnecessary weight. Generally speaking 10AWG is used for big LiPos >5000 mAH, 12AWG for LiPos >3,300 mAH, 14AWG for small LiPos >2000 mAH, 16/18AWG for mini LiPos >1000 mAH and finally 20-24AWG for receiver batteries, LED & low power lighting. Typically wire gauge requirements reduce as you progress away from the batteries; cable leading from the battery to the PDB/ESCs needs to be thicker than those connecting the flight electronics and auxiliaries. If cable lengths are kept short, you can usually “get away with” a higher current draw than the cable’s indicated rating. Current load can also be spread between multiple cables. For instance if you run two batteries in parallel you can run wires from each to a single PDB to in effect reduce the load running through the single wires. Finally avoid mixing wire gauges inline, as a lot of heat will be generated at the junction.
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