Wire size? - Page 1
Forum section: electronics / beginners

author: jjrbus
author_rank: Contributor
timestamp: May 12, 2025, 06:46:32 pm
content: Me again. I need to add a 16 pin connector but cannot figure out what wire ga I need. I cannot cut and strip this wire to measure. The electronic caliper shows 1.4 to 1.5 mm outside diameter. any guess on what size wire I am dealing with. This is in a Honda ER2200i generator. I cannot add a picture for some reason?

author: benj38
author_rank: Frequent Contributor
timestamp: May 12, 2025, 08:56:43 pm
content: Quote from: jjrbus on May 12, 2025, 06:46:32 pmSee this thread on how to add an image to your post. It is indeed confusing.https://www.eevblog.com/forum/chat/best-way-to-post-pictures-on-eevblog/

author: jjrbus
author_rank: Contributor
timestamp: May 12, 2025, 09:30:24 pm
content: Only a picture of the calipers showing 1.5mm on the wire. Lets see what happens this timeDrag and drop worked!

author: benj38
author_rank: Frequent Contributor
timestamp: May 12, 2025, 09:44:06 pm
content: Since the thickness of the insulation can vary dramatically, a measurement of the overall diameter including the insulation provides little information (except, of course, for an upper-bound).On the other hand, most connectors can accept only a very narrow range of wire gauges, so we can gain much more information this way.Please take a few pictures of one of the connectors from a few angles, andcarefullymeasure the distance between the centers of two adjacent holes. This should allow us to identify the connector and zoom in on the relevant wire diameter.

author: tooki
author_rank: Super Contributor
timestamp: May 12, 2025, 10:08:55 pm
content: Quote from: jjrbus on May 12, 2025, 06:46:32 pmWhile I completely agree with benj38’s requests for information (to which I will add that pictures should be sharp, in focus, for which you need ample light), the most common PVC-insulated wire types (e.g. UL1007, LiY) with ~1.5mm insulation diameter are 24AWG or 0.22-0.25mm2. But depending on insulation type and material, it could be anywhere from 26AWG to 20AWG. As benj38 said, identifying the connector itself will give you information on the wire range in question.I’d be rather surprised if none of the 16 wires you have in front of you has the wire specs (gauge or cross-section, type, and voltage) printed on it. Especially for US-sold electrical appliances (where UL listing is generally required), the wires inside are usually UL-listed, too, and to that end they’re printed with their UL wire style.

author: IanB
author_rank: Super Contributor
timestamp: May 12, 2025, 10:17:00 pm
content: Quote from: jjrbus on May 12, 2025, 06:46:32 pmIf you need to add a 16 pin connector, then presumably there is a mating connector that it connects to? So first figure out what connector you need. Then the connector specification will say what wire gauges it can accept. Use wires that are compatible with the connector.

author: jjrbus
author_rank: Contributor
timestamp: May 13, 2025, 01:25:17 am
content: You guys bailed me out again, thanks so much. I had to cut open the harness but almost legible is AWG 22. Wonderful Thai is clear as day on the wire. I have looked and looked for the mating connector, even asked here and seems to be unavailable.