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Azle, TX 76020

 
 
Wiring Tools and Reference
These tools may help you pick out the correct wire size for the circuit you need to build/repair.  use the Circular Mils Formula to determine the minimum circular mil value that your wire/cable must have first:
CM = [(2D)(I)(10.8)]/Vd
2D = twice the one-way wire distance in the circuit.  Ideally, you would want to replace the 2D term with an ACTUAL total wire distance measurement.

I = The Maximum Current required in the circuit at 100% duty cycle

10.8 = an electrical constant the origin of which I cannot recall

Vd = Maximum allowed DC voltage drop in the circuit which is arrived at by multiplying the regulation percentage by the nominal circuit voltage.  (e.g. 1% x 12vdc = 0.120vdc max)

 
Revised AWG Wire Table
(AWG Wire Table for BARE COPPER Wire Compiled by a program written by Fr. Tom McGahee)
Use the result from the Circular Mils formula in column 5 of this table to find the minimum wire size required to meet set specifications.  Although this table may be setup based on solid core copper wire, the "real-world" values I have measured are pretty close in the 2-30GA  and 4-60" "D" range.
AWG Dia-mils TPI Dia-mm Circ-mils Ohms/Kft Ft/Ohm Ft/Lb Ohms/Lb Lb/Kft NormAmps MaxAmps
0000 459.99 2.174 11.684 211592 0.049 20402 1.5613 0.0001 640.48 423.18 482.55
000 409.63 2.4412 10.405 167800 0.0618 16180 1.9688 0.0001 507.93 335.6 382.68
00 364.79 2.7413 9.2657 133072 0.0779 12831 2.4826 0.0002 402.8 266.14 303.48
0 324.85 3.0783 8.2513 105531 0.0983 10175 3.1305 0.0003 319.44 211.06 240.67
1 289.29 3.4567 7.348 83690 0.1239 8069.5 3.9475 0.0005 253.33 167.38 190.86
2 257.62 3.8817 6.5436 66369 0.1563 6399.4 4.9777 0.0008 200.9 132.74 151.36
3 229.42 4.3588 5.8272 52633 0.197 5075 6.2767 0.0012 159.32 105.27 120.03
4 204.3 4.8947 5.1893 41740 0.2485 4024.7 7.9148 0.002 126.35 83.48 95.19
5 181.94 5.4964 4.6212 33101 0.3133 3191.7 9.9804 0.0031 100.2 66.203 75.489
6 162.02 6.1721 4.1153 26251 0.3951 2531.1 12.585 0.005 79.46 52.501 59.866
7 144.28 6.9308 3.6648 20818 0.4982 2007.3 15.869 0.0079 63.014 41.635 47.476
8 128.49 7.7828 3.2636 16509 0.6282 1591.8 20.011 0.0126 49.973 33.018 37.65
9 114.42 8.7396 2.9063 13092 0.7921 1262.4 25.233 0.02 39.63 26.185 29.858
10 101.9 9.814 2.5881 10383 0.9989 1001.1 31.819 0.0318 31.428 20.765 23.678
11 90.741 11.02 2.3048 8233.9 1.2596 793.93 40.122 0.0505 24.924 16.468 18.778
12 80.807 12.375 2.0525 6529.8 1.5883 629.61 50.593 0.0804 19.765 13.06 14.892
13 71.961 13.896 1.8278 5178.3 2.0028 499.31 63.797 0.1278 15.675 10.357 11.81
14 64.083 15.605 1.6277 4106.6 2.5255 395.97 80.447 0.2031 12.431 8.2132 9.3654
15 57.067 17.523 1.4495 3256.7 3.1845 314.02 101.44 0.323 9.8579 6.5134 7.4271
16 50.82 19.677 1.2908 2582.7 4.0156 249.03 127.91 0.5136 7.8177 5.1654 5.89
17 45.257 22.096 1.1495 2048.2 5.0636 197.49 161.3 0.8167 6.1997 4.0963 4.6709
18 40.302 24.813 1.0237 1624.3 6.3851 156.62 203.39 1.2986 4.9166 3.2485 3.7042
19 35.89 27.863 0.9116 1288.1 8.0514 124.2 256.47 2.0648 3.8991 2.5762 2.9376
20 31.961 31.288 0.8118 1021.5 10.153 98.496 323.41 3.2832 3.0921 2.043 2.3296
21 28.462 35.134 0.7229 810.1 12.802 78.111 407.81 5.2205 2.4521 1.6202 1.8475
22 25.346 39.453 0.6438 642.44 16.143 61.945 514.23 8.3009 1.9446 1.2849 1.4651
23 22.572 44.304 0.5733 509.48 20.356 49.125 648.44 13.199 1.5422 1.019 1.1619
24 20.101 49.75 0.5106 404.03 25.669 38.958 817.66 20.987 1.223 0.8081 0.9214
25 17.9 55.866 0.4547 320.41 32.368 30.895 1031.1 33.371 0.9699 0.6408 0.7307
26 15.94 62.733 0.4049 254.1 40.815 24.501 1300.1 53.061 0.7692 0.5082 0.5795
27 14.195 70.445 0.3606 201.51 51.467 19.43 1639.4 84.371 0.61 0.403 0.4596
28 12.641 79.105 0.3211 159.8 64.898 15.409 2067.3 134.15 0.4837 0.3196 0.3644
29 11.257 88.83 0.2859 126.73 81.835 12.22 2606.8 213.31 0.3836 0.2535 0.289
30 10.025 99.75 0.2546 100.5 103.19 9.6906 3287.1 339.18 0.3042 0.201 0.2292
31 8.9276 112.01 0.2268 79.702 130.12 7.685 4145 539.32 0.2413 0.1594 0.1818
32 7.9503 125.78 0.2019 63.207 164.08 6.0945 5226.7 857.55 0.1913 0.1264 0.1441
33 7.0799 141.24 0.1798 50.125 206.9 4.8332 6590.8 1363.6 0.1517 0.1003 0.1143
34 6.3048 158.61 0.1601 39.751 260.9 3.8329 8310.8 2168.1 0.1203 0.0795 0.0907
35 5.6146 178.11 0.1426 31.524 328.99 3.0396 10480 3447.5 0.0954 0.063 0.0719
36 5 200 0.127 25 414.85 2.4105 13215 5481.7 0.0757 0.05 0.057
37 4.4526 224.59 0.1131 19.826 523.11 1.9116 16663 8716.2 0.06 0.0397 0.0452
38 3.9652 252.2 0.1007 15.723 659.63 1.516 21012 13859 0.0476 0.0314 0.0359
39 3.5311 283.2 0.0897 12.469 831.78 1.2022 26496 22037 0.0377 0.0249 0.0284
40 3.1445 318.01 0.0799 9.888 1048.9 0.9534 33410 35040 0.0299 0.0198 0.0226
AWG = American Wire Gauge size
Dia-mils = Diameter in mils (1 mil = .001 inch) 
TPI = Turns Per Inch (Ignoring thickness of unknown insulation) 
Dia-mm = Diameter in millimeters (For comparison with non-USA coilers) 
Circ-mils = Circular Mils. (circular mils = diameter in mils squared) 
Ohms/Kft = Ohms Per 1,000 Feet 
Ft/Ohm = Feet Per Ohm 
Ft/Lb = Feet Per Pound 
Ohms/Lb = Ohms Per Pound 
Lb/Kft = Pounds Per 1,000 Feet 
NormAmps = Normal Average Amp Capacity based on 500 circular mils per Amp 
MaxAmps = Maximum recommended Average Amp Capacity in Open Air based on 438.489 circular mils per Amp
 

 

Copyright (C)2003 MONTAC Enterprises.  All Rights Reserved©
Revised: March 03, 2006 .