White Paper - Determine Wire Gauge Insulation Type For A System Current Requirement Rev A

Technical Paper
Determine wire gauge (AWG) &

insulation type for a system current
(amperes) requirement
Ray-Q Ltd.
Gilboa St.
Ben-Gurion Airport City
70100, Israel
White Paper
List of Revisions
Rev.
Change Description
Date
New
A
First Issue
Update
02/09
08/11
Copyright Ray-Q Ltd.

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300
DETERMINE WIRE GAUGE (AWG) &

INSULATION TYPE FOR A SYSTEM
CURRENT (AMPERES) REQUIREMENT
80880818//
Rev. A
Page 2 of 15
White Paper
Can a conductor rated at 10 amps carry 10 amps? Maybe yes probably not. The
reason lies in the test conditions used to rate the conductor. If these conditions do
not adequately reflect application conditions, actual allowable current levels may
be lower than specified levels.
For example, many manufacturers test a single conductor in air. This gives an
accurate measure of the basic current-carrying capacity of the conductor. Use the
conductor alone in air and it can certainly carry 10 amps. Use it in a multi position
conductors surrounded by other current-carrying conductor or in high ambient
temperatures and the conductor should carry less current.
This technical paper was composed in order to help the designer set the
appropriate current level and specified the current carrying capacity (ampacity) of
a wire or harness.

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 3 of 15
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The ampacity is the maximum amount of current an insulated conductor can carry
without heating beyond a safe limit. Major influences are:
1. Conductor Size: The larger the cross section area, the greater the current
carrying capacity.
2. Temperature Rating: Wires and cables are rated for continuous operation
temperature. The wire temperature ratings in this technical paper are in
according to common applications:
Marine Application: 90C and 105C
Ground Application: 125C and 150C
Airborne Application: 150C and 200C
Space application: 200C
3. Conductor material: Ampacity is affected by conductivity. Thus the
ampacity of an aluminum conductor is approximately 80% that of the same
size copper conductor.
4. Insulation Material: The amount of heat generated should never exceed
the maximum temperature rating of the insulation. Therefore, the higher
the temperature rating of the insulation, the greater current carrying
capacity of the wire.
5. Ambient Temperature: The higher the ambient temperature, the less heat
required to exceed the maximum temperature rating of the insulation.
6. Installation Method: In air, conduit, duct, tray or direct burial. Bundling,
stacking and spacing all affect heat dissipation.
7. Installation Environment: Heat dissipation by conduction, convection,
forced air flow, altitude, air conditioning etc.
8. Number of conductors: Single conductors have a higher ampacity rating
than equivalent size conductors bundled in a cable.
Heat dissipation is lessened as the number of individually insulated
conductors, bundled together, is increased.
9. Amperage: Heat increase is not linear; it varies as the square of the
applied current.

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 4 of 15
White Paper
These many factors make it impossible to construct a general chart for ampacity.
The values shown in Table 1 are MAXIMUM for a single conductor in free air,
based on ambient temperature of 30C at sea level, enabling a temperature rise
fit for different wire types.
For cable or harness with two (2) or three (3) conductors use Table 2.
For cable or harness with more than three (3) conductors, make circuit analysis
for the bundle to define the percentages of wires in the bundle that carrying power
current nearly at or up to capacity. Use correction factor in Table 4 to correct the
values in Table 1.
For actual use temperatures above an ambient temperature of 30C, reduce the
maximum ampacity by use of correction factor in Table 3 to correct the values in
Table 1 and Table 2.
For altitude above sea level, reduce the maximum ampacity by use of correction
factor in Table 5 to correct the values in Table 1 and Table 2.

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 5 of 15
White Paper
Table 1: Lead Wire Current Carrying Capacity

(Amperes per Conductor)
AWG
90C
105C
125C
150C
200C
30
28
3
4
3
4
3
5
3
5
4
6
26
24
22
20
18
16
14
12
10
5
7
10
13
18
22
30
40
55
5
7
11
14
20
25
33
45
60
6
8
12
15
22
26
37
50
65
6
8
14
18
24
28
42
55
75
7
10
16
21
28
32
50
68
88
8
6
4
2
1
1/0
2/0
3/0
4/0
80
105
140
190
220
260
300
350
405
90
121
160
215
247
286
329
380
446
97
131
172
232
266
309
355
410
481
106
155
190
255
293
339
390
451
529
124
165
220
293
344
399
467
546
629
Note:
1. Values (amperes) shown in this table are maximum for a single conductor
in free air with an assumed ambient temperature of 30C, and altitude at
sea level.

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 6 of 15
White Paper
Table 2: Current Carrying Capacity of 2 or 3 conductors

(Amperes per Conductor)
AWG
90C
105C
125C
150C
200C
30
28
26
1
2
3
2
3
3
2
3
4
2
3
4
3
4
4
24
22
20
18
16
14
12
10
8
6
8
14
7
9
15
8
10
16
9
13
17
10
15
20
18
25
30
40
55
19
29
36
46
64
20
31
39
50
69
22
34
43
55
76
25
36
45
60
83
75
95
130
150
170
195
225
260
81
109
143
168
193
229
263
301
87
118
154
181
208
247
284
325
96
120
160
186
215
251
288
332
110
125
171
197
229
260
297
346
6
4
2
1
1/0
2/0
3/0
4/0
Notes:
1. Current carrying capacity of not more than three (3) conductors within a
cable, tubing, conduit or bundled together.
2. The values (amperes) shown in this table are maximum at an assumed
ambient room temperature of 30C at sea level altitude.

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 7 of 15
White Paper
Table 3: Ambient temperatures Correction factors for

Table 1 & Table 2
Ambient
Temperature
(C)
31 35
36 40
41 45
46 50
51 55
56 60
61 70
71 80
81 90
91 100
101 120
121 140
141 160
161 - 180
Insulation Temperature Rating

90C
105C
125C
150C
200C
0.96
0.91
0.87
0.82
0.76
0.71
0.58
0.41
1.00
1.00
0.93
0.93
0.85
0.85
0.76
0.65
0.53
0.38
1.00
1.00
0.94
0.94
0.87
0.87
0.80
0.73
0.64
0.54
0.24
1.00
1.00
0.95
0.95
0.90
0.90
0.85
0.80
0.74
0.67
0.52
0.30
1.00
1.00
0.97
0.97
0.94
0.94
0.90
0.87
0.83
0.79
0.71
0.61
0.50
0.35
Note:
1. For ambient temperatures over 30C, multiply the ampacities shown in
Table 1 or Table 2 by the appropriate correction factor to determine the
maximum allowable load current.

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 8 of 15
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Table 4: More than three conductor correction factor for

Table 1
Number of
Conductors
4 thru 6
7 thru 9
10 thru 20
21 thru 30
31 thru 40
41 and above
20%
0.85
0.80
0.65
0.60
0.55
0.50
Bundle Loading Percentage

40%
60%
80%
0.75
0.70
0.65
0.65
0.60
0.55
0.55
0.55
0.40
0.45
0.40
0.35
0.40
0.35
0.30
0.35
0.30
0.30
100%
0.60
0.50
0.35
0.30
0.25
0.25
Note:
1. If more than three (3) conductors are in a cable, tubing, and conduit or
bundled together; the values given in Table 1 must be reduced using the
above correction factor.
2. Make circuit analysis for the bundle to define the percentages of wires in
the bundle that carrying power current nearly at or up to capacity.

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 9 of 15
White Paper
Table 5: Above sea level correction factor for

Table 1 & Table 2
Altitude (ft)
Correction factor
1,000 thru 5,000

5,001 thru 10,000
10,001 thru 15,000
15,001 thru 20,000
20,001 thru 30,000
30,001 thru 40,000
40,001 thru 50,000
50,001 thru 60,000
60,001 thru 70,000
70,001 thru 80,000
80,001 thru 90,000
90,001 thru 100,000
100,001 and above
Vacuum
0.975
0.950
0.925
0.900
0.875
0.850
0.825
0.800
0.775
0.750
0.725
0.700
0.600
0.500
Note:
1. If above sea level the values given in Table 1 & Table 2 must be reduced
using the above correction factor

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 10 of 15
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Example:
Application: airborne
System Maximum Current: 8 amps.
Cable: 12 wires bundle, 6 wires carrying power currents nearly at or up to
capacity.
Ambient temperature: 70C.
Altitude: 60,000 ft
Step 1:
Refer to Table 1 determine the AWG and the current of the wire required for the
application. Since the application is airborne and the required wire temperature
rate is 150C the free air rating for size #22 is 14 amps, and the free air rating for
size #20 is 18 amps.
Step 2:
Refer to Table 4 ("More than three conductor correction factors"). For a 12
conductor bundle use "10 thru 20" (on the first column). Since there are 12 wires
in the bundle and only 6 wires carrying power currents nearly at or up to capacity,
the bundle loading percentage would be:
12 wires / 6 wires = 50%
To be on the safe side the correction factor will calculate for Bundle Loading
Percentage of 60%. Therefore the correction factor to use would be 0.55.
Alternate #1
Table 1 state 14 amps for 22 AWG @ 150C, but when derated for bundle size
the actual rating is:
22 AWG 14 [Amps] X 0.55 [correction factor] = 7.7 Amps.
The result gives out a rating of 7.7 Amps which is insufficient for the application.
Alternate #2
20 AWG 18 [Amps] X 0.55 [correction factor] = 9.9 Amps.
The result gives out a rating of 9.9 Amps which is sufficient for the application.

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 11 of 15
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Alternate #3
18 AWG 24 [Amps] X 0.55 [correction factor] = 13.2 [Amps].
Step 3:
Refer to Table 3 Ambient temperatures Correction factors, look for 70C. Since
that is the temperature at which the application will be operating and the wire
temperature rating is 150C. Determine that the wire correction factor to be 0.85.
Alternate #1
Calculate the derated ampacity of the 20 AWG wire by multiplying with the
correction factor from Table 3:
20 AWG 9.9 [Amps] X 0.85 [correction factor] = 8.415 Amps.
Alternate #2
18 AWG 13.2 [Amps] X 0.85 [correction factor] = 11.22 Amps.

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 12 of 15
White Paper
Step 4:
Refer to Table 5 Above sea level correction factor look for 60,000 feet (on the
first column). Since that is the temperature at which the application will be
operating. Determine that the wire correction factor to 80%.
Alternate #1
20 AWG 8.415 [Amps] X 0.8 [correction factor] = 6.732 [Amps].
The result gives out a rating of 6.732 Amps which is insufficient for the
application.
Alternate #2
18 AWG 11.22 [Amps] X 0.8 [correction factor] = 8.976 [Amps].

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 13 of 15
White Paper
Appendix A: Charts
METRIC/AWG WIRE SIZE EQUIVALENTS
In Europe wire and cable sizes are expressed in mm2 (cross sectional area),
while in US the AWG (American Wire Gauge) is the standard system used for
both solid and strand conductors. See below for the cross reference scheme.
Sq. MM
AWG
0.05
0.08
0.14
0.25
0.34
0.50
0.75
1.00
1.50
2.50
4.00
6.00
10.00
16.00
25.00
35.00
50.00
70.00
95.00
120.00
30
28
26
24
22
20
18
17
16
14
12
10
8
6
4
2
1
2/0
3/0
4/0
Note:
1. Cross references are approximated

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300

80880818//
Rev. A
Page 14 of 15
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Fahrenheit (F) to Celsius (C) conversion

F
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0
25.0
26.0
27.0
28.0
29.0
30.0
31.0
32.0
33.0
34.0
35.0
36.0
37.0
38.0
39.0
40.0
41.0
42.0
43.0
44.0
45.0
46.0
47.0
48.0
49.0
50.0
C
-17.2
-16.7
-16.1
-15.6
-15.0
-14.4
-13.9
-13.3
-12.8
-12.2
-11.7
-11.1
-10.6
-10.0
-9.4
-8.9
-8.3
-7.8
-7.2
-6.7
-6.1
-5.6
-5.0
-4.4
-3.9
-3.3
-2.8
-2.2
-1.7
-1.1
-0.6
0.0
0.6
1.1
1.7
2.2
2.8
3.3
3.9
4.4
5.0
5.6
6.1
6.7
7.2
7.8
8.3
8.9
9.4
10.0

Gilboa St.
70100, Israel
Tel: (972) 3 9753333
Fax: (972) 3 9753300
F
51.0
52.0
53.0
54.0
55.0
56.0
57.0
58.0
59.0
60.0
61.0
62.0
63.0
64.0
65.0
66.0
67.0
68.0
69.0
70.0
71.0
72.0
73.0
74.0
75.0
76.0
77.0
78.0
79.0
80.0
81.0
82.0
83.0
84.0
85.0
86.0
87.0
88.0
89.0
90.0
91.0
92.0
93.0
94.0
95.0
96.0
97.0
98.0
99.0
100.0
C
10.6
11.1
11.7
12.2
12.8
13.3
13.9
14.4
15.0
15.6
16.1
16.7
17.2
17.8
18.3
18.9
19.4
20.0
20.6
21.1
21.7
22.2
22.8
23.3
23.9
24.4
25.0
25.6
26.1
26.7
27.2
27.8
28.3
28.9
29.4
30.0
30.6
31.1
31.7
32.2
32.8
33.3
33.9
34.4
35.0
35.6
36.1
36.7
37.2
37.8
F
101.0
102.0
103.0
104.0
105.0
106.0
107.0
108.0
109.0
110.0
111.0
112.0
113.0
114.0
115.0
116.0
117.0
118.0
119.0
120.0
121.0
122.0
123.0
124.0
125.0
126.0
127.0
128.0
129.0
130.0
131.0
132.0
133.0
134.0
135.0
136.0
137.0
138.0
139.0
140.0
141.0
142.0
143.0
144.0
145.0
146.0
147.0
148.0
149.0
150.0
C
38.3
38.9
39.4
40.0
40.6
41.1
41.7
42.2
42.8
43.3
43.9
44.4
45.0
45.6
46.1
46.7
47.2
47.8
48.3
48.9
49.4
50.0
50.6
51.1
51.7
52.2
52.8
53.3
53.9
54.4
55.0
55.6
56.1
56.7
57.2
57.8
58.3
58.9
59.4
60.0
60.6
61.1
61.7
62.2
62.8
63.3
63.9
64.4
65.0
65.6
F
151.0
152.0
153.0
154.0
155.0
156.0
157.0
158.0
159.0
160.0
161.0
162.0
163.0
164.0
165.0
166.0
167.0
168.0
169.0
170.0
171.0
172.0
173.0
174.0
175.0
176.0
177.0
178.0
179.0
180.0
181.0
182.0
183.0
184.0
185.0
186.0
187.0
188.0
189.0
190.0
191.0
192.0
193.0
194.0
195.0
196.0
197.0
198.0
199.0
200.0
C
66.1
66.7
67.2
67.8
68.3
68.9
69.4
70.0
70.6
71.1
71.7
72.2
72.8
73.3
73.9
74.4
75.0
75.6
76.1
76.7
77.2
77.8
78.3
78.9
79.4
80.0
80.6
81.1
81.7
82.2
82.8
83.3
83.9
84.4
85.0
85.6
86.1
86.7
87.2
87.8
88.3
88.9
89.4
90.0
90.6
91.1
91.7
92.2
92.8
93.3
F
201.0
202.0
203.0
204.0
205.0
206.0
207.0
208.0
209.0
210.0
211.0
212.0
213.0
214.0
215.0
216.0
217.0
218.0
219.0
220.0
221.0
222.0
223.0
224.0
225.0
226.0
227.0
228.0
229.0
230.0
231.0
232.0
233.0
234.0
235.0
236.0
237.0
238.0
239.0
240.0
241.0
242.0
243.0
244.0
245.0
246.0
247.0
248.0
249.0
250.0
C
93.9
94.4
95.0
95.6
96.1
96.7
97.2
97.8
98.3
98.9
99.4
100.0
100.6
101.1
101.7
102.2
102.8
103.3
103.9
104.4
105.0
105.6
106.1
106.7
107.2
107.8
108.3
108.9
109.4
110.0
110.6
111.1
111.7
112.2
112.8
113.3
113.9
114.4
115.0
115.6
116.1
116.7
117.2
117.8
118.3
118.9
119.4
120.0
120.6
121.1
F
251.0
252.0
253.0
254.0
255.0
256.0
257.0
258.0
259.0
260.0
261.0
262.0
263.0
264.0
265.0
266.0
267.0
268.0
269.0
270.0
271.0
272.0
273.0
274.0
275.0
276.0
277.0
278.0
279.0
280.0
281.0
282.0
283.0
284.0
285.0
286.0
287.0
288.0
289.0
290.0
291.0
292.0
293.0
294.0
295.0
296.0
297.0
298.0
299.0
300.0
C
121.7
122.2
122.8
123.3
123.9
124.4
125.0
125.6
126.1
126.7
127.2
127.8
128.3
128.9
129.4
130.0
130.6
131.1
131.7
132.2
132.8
133.3
133.9
134.4
135.0
135.6
136.1
136.7
137.2
137.8
138.3
138.9
139.4
140.0
140.6
141.1
141.7
142.2
142.8
143.3
143.9
144.4
145.0
145.6
146.1
146.7
147.2
147.8
148.3
148.9
F
301.0
302.0
303.0
304.0
305.0
306.0
307.0
308.0
309.0
310.0
311.0
312.0
313.0
314.0
315.0
316.0
317.0
318.0
319.0
320.0
321.0
322.0
323.0
324.0
325.0
326.0
327.0
328.0
329.0
330.0
331.0
332.0
333.0
334.0
335.0
336.0
337.0
338.0
339.0
340.0
341.0
342.0
343.0
344.0
345.0
346.0
347.0
348.0
349.0
350.0
C
149.4
150.0
150.6
151.1
151.7
152.2
152.8
153.3
153.9
154.4
155.0
155.6
156.1
156.7
157.2
157.8
158.3
158.9
159.4
160.0
160.6
161.1
161.7
162.2
162.8
163.3
163.9
164.4
165.0
165.6
166.1
166.7
167.2
167.8
168.3
168.9
169.4
170.0
170.6
171.1
171.7
172.2
172.8
173.3
173.9
174.4
175.0
175.6
176.1
176.7
F
351.0
352.0
353.0
354.0
355.0
356.0
357.0
358.0
359.0
360.0
361.0
362.0
363.0
364.0
365.0
366.0
367.0
368.0
369.0
370.0
371.0
372.0
373.0
374.0
375.0
376.0
377.0
378.0
379.0
380.0
381.0
382.0
383.0
384.0
385.0
386.0
387.0
388.0
389.0
390.0
391.0
392.0
393.0
394.0
395.0
396.0
397.0
398.0
399.0
400.0
C
177.2
177.8
178.3
178.9
179.4
180.0
180.6
181.1
181.7
182.2
182.8
183.3
183.9
184.4
185.0
185.6
186.1
186.7
187.2
187.8
188.3
188.9
189.4
190.0
190.6
191.1
191.7
192.2
192.8
193.3
193.9
194.4
195.0
195.6
196.1
196.7
197.2
197.8
198.3
198.9
199.4
200.0
200.6
201.1
201.7
202.2
202.8
203.3
203.9
204.4

80880818//
Rev. A
Page 15 of 15

White Paper - Determine Wire Gauge Insulation Type For A System Current Requirement Rev A

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Technical Paper

Determine wire gauge (AWG) &

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Table 1: Lead Wire Current Carrying Capacity

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Table 2: Current Carrying Capacity of 2 or 3 conductors

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Table 3: Ambient temperatures Correction factors for

Insulation Temperature Rating

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Table 4: More than three conductor correction factor for

Bundle Loading Percentage

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Table 5: Above sea level correction factor for

1,000 thru 5,000

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

Fahrenheit (F) to Celsius (C) conversion

Copyright Ray-Q Ltd.

DETERMINE WIRE GAUGE (AWG) &

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