Sep. 01, 2025
Choosing the right wire and cable is crucial for the safety and efficiency of any electrical system. Whether you're working on a home project, industrial installation, or commercial application, selecting the correct wire and cable ensures optimal performance and reduces the risk of electrical hazards. Here are ten essential tips to help you make the right choice.
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Before you start shopping for wires and cables, it's important to understand your specific needs. Consider the type of application, the amount of power required, and the environment in which the cables will be used. Knowing these details will help you narrow down your options and select the most suitable wire and cable.
Each wire and cable comes with a voltage rating, indicating the maximum voltage it can safely carry. Ensure that the voltage rating of the wire matches or exceeds the voltage of your application to prevent overheating and potential electrical failures.
The current-carrying capacity, or ampacity, is the maximum amount of current a wire can carry without overheating. Choose a wire with an ampacity that matches or exceeds the current requirements of your application. Using a wire with insufficient ampacity can lead to overheating and fire hazards.
Wire gauge refers to the thickness of the wire, with lower numbers indicating thicker wires. Thicker wires can carry more current and are less prone to voltage drops. For long-distance applications, choose a thicker wire to minimize energy loss and ensure efficient power transmission.
Environmental conditions play a significant role in wire and cable selection. Factors such as temperature, humidity, exposure to chemicals, and mechanical stress can affect the performance and longevity of the cables. Choose wires and cables with appropriate insulation and jacket materials to withstand the specific environmental conditions of your application.
Some applications require wires and cables to be flexible and capable of bending without damage. Consider the flexibility and bend radius of the cable, especially if it will be routed through tight spaces or subjected to frequent movement.
Ensure that the wires and cables you choose meet industry standards and certifications. Look for markings such as UL (Underwriters Laboratories), CSA (Canadian Standards Association), or IEC (International Electrotechnical Commission). These certifications guarantee that the cables meet safety and performance standards.
In environments with high electromagnetic interference (EMI), such as industrial settings or areas with heavy machinery, using shielded cables can prevent signal degradation and ensure reliable performance. Determine if your application requires shielding and choose the appropriate type of shielded cable.
When selecting wires and cables, consider potential future expansion. Choosing cables with higher capacity than currently needed can save time and money in the long run by accommodating future upgrades without the need for rewiring.
If you're unsure about the right wire and cable for your application, consult with a professional electrician or a cable supplier. They can provide expert advice and help you make an informed decision based on your specific requirements.
Armor-Clad (AC) Cable: AC cable includes THHN-insulated conductors with 16-gauge aluminum bond wire placed inside the armor to act as a grounding conductor.
Automotive Cable: This is a general-purpose thermoplastic (GPT) wire, also referred to as primary wire. Normal applications are within motor vehicles with limited exposure to fluids, physical wear and abuse.
Bayonet Neill-Concelman (BNC) Cable: BNC cables are small, quick-connect/disconnect radio frequency connectors used for coaxial cables.
Category Cable: This is used for systems and data networking systems. Cat 5e is the most common variety of category cable that’s used for computer networking on internet service installations. The conductor pairs are twisted together to prevent cross-talk and interference from other paired conductors in the cable, as well as external interference. The higher the megahertz (MHz) capability, the more twists per foot.
Coaxial Cable: This is a metallic cable that carries television and video signals. It connects to video equipment and features a central conductor with a dielectric insulator, metallic shield and plastic jacket.
Doorbell Wire: Doorbell wire is used to connect a wired doorbell or video doorbell to a home’s electrical system. 18-gauge wire is the variety most often used.
Dual Armored Cable: This is a durable cable that offers protection without employing electrical conduit, elbows, offsets (which can be expensive) or conduit couplings. For areas where the cable may be exposed to moisture, metal-clad armor prevents corrosion.
Flexible Cord: Typically used for industrial machinery, washing machines and large appliances, portable tools, equipment, and extension or power cords, flexible/power cord has its own naming convention based on a letter code, with a common option being SJEOOW.
Lamp Cord: Used with lamps, small appliances, radios and other similar products that don’t exceed 300 volts, lamp cord is available between 18- and 12-gauge sizes in a variety of colors.
Landscape Lighting Low-Voltage (LV) Cable: This underground cable is suitable for outdoor accent lighting, landscape lighting and security lighting. Applications shouldn’t exceed 150 volts. It’s used for direct burial, is suitable for sunlight and is available between 16- and 8-gauge sizes.
Metal-Clad (MC) Cable: MC cable is used heavily in commercial electrical work, for running through concrete or in other commercial environments. Individual THHN wire conductors are run through an aluminum interlocked armor. It includes a grounding wire.
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Mobile Home Feeder: This connects a mobile home to a supply of electricity where permanent wiring is required, and it’s suitable for direct burial and underground service entrance cable. It includes four RHH or RHW-2 conductors, with a white stripe for neutral and a green ground conductor. It’s sunlight-resistant.
Network and Data Cable: This comes in three types — fiber-optic, twisted-pair and coaxial cable — and is used to connect multiple networking devices or computers in a network.
NM-B: This is a non-metallic sheathed cable that’s used as a residential building wire for branch circuits for outlets, lighting and other residential applications. NM-B is available between 14 AWG and 6 AWG with two or three conductors.
Preassembled Whips: These are pre-cut lengths of armored cable designed to increase jobsite productivity. Assembly comes with pre-stripped THHN conductors and pre-installed zinc die-cast, snap-in fittings.
Residential Grounding Wire: This is bare copper wire that’s available in 4-, 6- and 8-gauge solid and stranded construction. It’s used to ground the residential electrical system, usually at the meter before it enters the dwelling. It’s also used for grounding the perimeter surface around pools.
Service Entrance Cable: This includes individual conductors rated XHHW-2 or THHN/THWN and feeds power from a main breaker to a subpanel. It can be exposed to direct sunlight and used in wet or dry locations.
Speaker Wire: Made of copper and designed to transport a low-voltage electrical current, speaker wire has a variety of wiring uses, including doorbells, thermostats, home security sensors, landscape lighting and other low-current systems.
Sprinkler Wire: Multi-conductor sprinkler wire is suitable for direct burial on applications up to 30 volts. It’s used in central controls for underground sprinkler systems and is available in 18-gauge construction with up to 25 conductors.
Submersible Pump Cable: This includes THWN copper conductors that are heat-, moisture-, oil- and gasoline-resistant. It’s suitable for temperatures below 75 degrees Celsius with two or three conductors. It’s used for power and circuits for submersible pump systems.
Thermostat Wire: Used in heating and air conditioning systems, along with bell and alarm systems, thermostat wire is available in 20- or 18-gauge sizes with up to 10 conductors.
Underground (UF-B) Wire: A copper wire used for underground purposes, including direct burial, it comes in a gray jacket and can be used for deck lighting, outdoor water features, landscape lighting and air conditioner compressors.
Underground Residential Distribution (URD) Cable: Used for secondary distribution and underground service applications at 600 volts or less, it’s suitable for direct burial or placement in ducts. It’s acceptable in wet locations in triplex or quadruplex. Conductors are stranded, compressed aluminum. The neutral conductor has a yellow, triple-extruded stripe.
When completing an electrical project, it’s important to have the right tools and safety equipment to get the job done. Check out some of the most common tools for an electricians tool box.
Boxes and Covers: These are used to house outlets and adapters for operating lights, ceiling fans, kitchen appliances, etc.
Circuit Breakers and Fuses: These are two devices for preventing an electrical current from causing damage by overloading or shorting a circuit. Breakers and fuses interrupt the current during an overload or short and are housed in a breaker box or fuse box. Homes built after the s typically use circuit breakers rather than fuses.
Electrical Tape: Used for repairing electrical cords or insulating a wire, electrical tape is typically black. It can be used to identify wires and should be stretched as you apply it for better adherence.
Electrical Testers: Checking a circuit to make sure it isn’t live can be a life-saving decision. An electrical tester will quickly inform you if you’re working with live cables or not.
Outlets and Adapters: When wires are connected to an outlet or adapter, it allows the electrical current to power anything plugged into it, such as a kitchen appliance.
Plugs and Connectors: These are usually run from an appliance or a power cord and are plugged into an outlet on the wall. They allow an appliance to receive power from an outlet.
Wire Connectors: These connect two wires together with a connector: The exposed end of each wire is put into the connector and twisted so that they’re connected. Check out our DIY Basics video: How Do I Connect Two Wires?
Wire/Cable Cutters: This tool is used to cut directly through wire and cable. There are a variety of cutters for different jobs, so check that you’re using the appropriate one, whether you’re cutting through copper wire or a network cable.
Wire Strippers: This device removes the plastic casing to expose the bare wire underneath. Most strippers offer multiple slots for a variety of wire sizes, while some have an adjustment dial to set the correct size. Simply insert a wire into the correct sized slot, twist and pull it through.
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