Comparing cables vs wires: Features, classifications and applications

1.1 What is an electrical wire?

An electrical wire is a single electrical conductor, which may be insulated or bare conductor, and is typically made of copper or aluminum. The insulation is a protective plastic layer applied directly over the conductor. In many cases, the term “wire” can be interpreted as an insulated conductor.

The cross-section of a wire is commonly specified using either the American Wire Gauge (AWG) standard or in square millimeters (mm²). AWG is a sizing system that determines the wire’s thickness based on the conductor’s diameter. The smaller the AWG number, the bigger the wire’s diameter and the higher its current-carrying capacity.

Although AWG is most often applied to solid wires, it is also used for stranded wires and cables. In these cases, the AWG value represents the total conductor cross-sectional diameter.

Learn about the significance of the AWG rating for electrical wires and cables

1.2 Function of wires

The primary function of an electrical wire is to provide a low-resistance pathway for electrons to flow from a power source to a load, thereby completing the circuit and enabling efficient energy transmission. Wires connect electrical components such as switches, outlets, and appliances, ensuring safe and controlled power distribution throughout the system.

1.3 Types of wires

There are two primary types of electrical wires: solid wire and stranded wire:

• Solid wire: The conductor consists of a single, continuous metal strand that can be bent to a certain extent. Solid wires offer lower electrical resistance and higher mechanical durability compared to stranded wires. They are often used in fixed installations or applications that require high-frequency performance.
• Stranded wire: Made up of multiple smaller solid strands twisted or braided together to form a single conductor. Stranded wires are typically insulated and are more flexible than solid wires, making them suitable for tight spaces or applications requiring frequent bending.

Both types of wires can also be incorporated as conductors within cable structures and may include additional protective insulation or jacketing depending on application requirements.

Another commonly used wire type is tinned copper wire. The tinning process involves coating the copper surface with a thin layer of tin, providing corrosion resistance, enhancing solderability, and preventing oxidation.

Examples of HELUKABEL tinned copper wire products include:
SOLARFLEX®-X H1Z2Z2-K NTS , THERMFLEX® 180 EWKF , TRAYCONTROL® 300-C TP, HELUDATA® TRONIC-CY 2464 / 300 GREY, and H HELUDATA® TRONIC-CY 2464 / 300 BLACK

1.5 Distinguishing phase, neutral, and ground wires

In an AC (alternating current) electrical system, three commonly used terms for electrical conductors are phase wire, neutral wire, and ground wire. Their differences are as follows:

• Phase wire (hot wire): This conductor carries voltage and delivers electrical energy to power devices and equipment.
• Neutral wire: This conductor does not normally carry current, but it completes the electrical circuit by returning current back to the source. In other words, the neutral wire provides a return path, enabling current to flow through the load. Without a neutral wire, the circuit would remain open and current would not flow.
• Ground wire (earthing/grounding conductor): This conductor safely channels any fault current to the earth — a zero-potential point — helping reduce the risk of electrical hazards. The ground wire is commonly identified with green-yellow insulation.

2.1 What are electrical cables?

An electrical cable is composed of multiple conductors bundled together, which may be layered, twisted, or braided. The basic structure of a cable typically includes: a conductor, insulation, and an outer sheath.

• Conductor: Responsible for transmitting electrical energy. Copper is commonly used due to its excellent conductivity, while other materials such as aluminum or copper-clad aluminum (CCA) are also applied.
• Insulation: Provides electrical isolation for the conductor, preventing current from flowing to unintended components or paths.
• Outer sheath: Protects the cable against mechanical impact, human contact, moisture, chemicals, and other environmental factors.

In addition, some electrical cables are reinforced with extra layers such as armouring or shielding to enhance mechanical strength or reduce electromagnetic interference (EMI).

Summary of essential information about electrical cables

2.2 Functions and applications of electrical cables

Electrical cables not only transmit power but also play a critical role throughout industrial systems. Depending on the cable type and specific application, electrical cables can serve one or multiple functions:

• Power transmission: Carry low, medium, or high voltage electricity to machinery, production equipment, and building power systems.
• Control signal transmission: Connect sensors and PLCs to ensure accurate and synchronized operation.
• Data and communication transmission: Network cables, fiber optic cables, and communication cables enable efficient operation of automation systems.
• Measurement signal transmission: Signal cables from temperature, pressure, and flow sensors ensure accurate and stable data.
• Safety and protection: Grounding wires, shielded cables, and fire-resistant cables help minimize electrical shock hazards, prevent fire risks, and maintain operation under emergency conditions.
• Motor control: Power and servo cables deliver power and control signals to motors and frequency inverters, requiring vibration resistance and EMC protection.
• Specialized applications: Rodent-resistant cables, chemical-resistant cables, outdoor-rated cables, and drag chain cables designed for harsh industrial environments.

2.3 Classification of electrical cables

Compared with wires, electrical cables are more diverse and classified based on multiple criteria. Some common classification methods include:

• By conductor material: Copper cables, aluminum cables, tinned copper cables, Class 5 flexible cables…
• By insulation and outer sheath materials: PVC, PUR, TPE, XLPE, rubber, silicone...
• By application: Control cables, data cables, fiber optic cables, audio cables, Ethernet network cables, reeling cables, servo motor cables, heat-resistant cables…
• By properties: Fire-resistant cables, flame-retardant cables, direct-burial cables, oil-resistant cables, chemical-resistant cables.
• By voltage rating: 0.6/1kV, 300/500V, 450/750V, 18/30kV…
• Other criteria: Number of cores (single-core, multi-core), cable structures (CV, CVV, CXV), and compliance with standards (IEC, DIN VDE, ECOLAB, UL/CSA).

Explore HELUKABEL's range of electrical cables for various industries

Whether electrical wires or cables, HELUKABEL offers a comprehensive connectivity solution for industrial applications with a catalog of more than 33,000 product items.

We provide a full range of bare copper conductors specifically designed for grounding and earthing applications, available in multiple configurations:

• Round single conductor, bare copper or tinned copper, from Class 2 to Class 6/7
• Round stranded conductor, bare copper or tinned copper, from Class 6/4 to Class 6/7