Cable, Wire & Assemblies
Cable and wire selection is extremely important when assembling an electrical design because it affects the overall safety, serviceability and usability of the application. The main difference between wire and cable is that wire is a single conductor that carries current through a circuit while cable is a collection of wires sheathed together.
Wire comes in various materials and sizes to accommodate different electrical loads. The two most important factors to help determine which type of wire is best for a project, are the gauge and length. The longer the wire, the greater the gauge needs to be to counteract the voltage drop lost through resistance.
Ethernet cable is a network cable that carries broadband signals between devices such as routers, PCs and switches. These cables are limited by length and quality and therefore, have Categories (Cat), which refer to different sets of standards. Ethernet cables that are Cat 5e and Cat 6e (or higher) are recommend for higher speeds.
Coax cable or coaxial cable is used to carry video, radio frequency and other forms of data signals. The cable has a copper core surrounded by an insulating layer and a conductive shielding. This design makes it ideal for industrial settings, where the cable is resistant to signal interference from devices such as motors and protected from damage due to environmental factors. Coax cable works best at high frequencies and shorter distances.
Fiber optic cable is a network cable that transmits data as pulses of light through fibers of glass or plastic inside an insulated casing. The fast data transmission over long distances make them ideal for high-performance data networking and telecommunications.
Industrial Wire Types: Part 1
THHN
Thermoplastic, High Heat resistant, Nylon jacket insulation (THHN) wire is used in conduit or in cable trays due to its rigidity and tough insulation characteristics. THHN can be stranded (several small strands of wire grouped together), allowing for more flexibility and less chance of breakage, or solid (one wire), which is more durable and rigid. THHN wire is suitable for use in dry locations with temperatures that do not exceed 90 degrees Celsius.
XHHW
Cross-linked polyethylene, High Heat-resistant, Water-resistant (XHHW) wire is very similar to THHN. The difference is that XHHW wire is overall a more durable wire that can withstand higher temperatures and is water resistant. XHHW wire can also be found in both stranded and solid wire options.
MTW
Machine Tool Wire (MTW) wire is much more flexible than THHN wire with insulation that is not as durable, making it a poor choice to run through conduit. The flexibility makes it ideal for winding through tight areas, such as wire ducting in an industrial control cabinet. MTW wire is almost exclusively found in stranded wire, which allows for much of the flexibility and reduces the chances of the wire breaking. MTW wire is intended for use in dry locations that do not exceed 90 degrees Celsius or wet locations that do not to exceed 60 degrees Celsius.