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Wires and preparation for control wiring

Electrical equipment uses a wide variety of wire and cable types and it is up to us to be able to correctly identify and use the wires which have been specified. The wrong wire types will cause operational problems and could render the unit unsafe.

Industrial control wiring guide
Industrial control wiring guide (photo credit:

Such factors include:

  • The insulation material;
  • The size of the conductor;
  • What it’s made of;
  • Whether it’s solid or stranded and flexible.

These are all considerations which the designer has to take into account to suit the final application of the equipment.

A conductor is a material which will allow an electric current to flow easily. In the case of a wire connection, it needs to be a very good conductor. Good conductors include most metals. The most common conductor used in wire is copper, although you may come across others such as aluminium. An insulator on the other hand is a material which does not allow an electric current to flow. Rubber and most plastics are insulators.

Preparing wire
Preparing wire

Insulation materials

Wires and cables (conductors) are insulated and protected by a variety of materials (insulators) each one having its own particular properties. The type of material used will be determined by the designer who will take into account the environment in which a control panel or installation is expected to operate as well as the application of individual wires within the panel.

As part of the insulating function, a material may have to withstand without failing:

  • Extremes of current or temperature;
  • A corrosive or similarly harsh environment;
  • Higher voltages than the rest of the circuit.

Because of these different properties and applications, it is essential that you check the wiring specification for the correct type to use.

Title:Industrial Control Wiring Guide by Bob Mercer
Size:1.40 MB
Download:Right here | Video Courses | Membership | Download Updates
Industrial Control Wiring Guide
Industrial Control Wiring Guide

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  1. Mike Ezugwu
    May 02, 2023

    This site teaches both Basic and real process in Advanced level. It is very impressive and further processes and relevant tools in electrical installations.

  2. Marlen
    Nov 08, 2021

    Good day,
    please assist me with a control plan template and examples on the following processess,
    1. wire preparation
    2. wire splicing
    3. splicing covering
    4. adhesive application
    5.board testing
    7.harness covering
    the above are elements for building a headlamp harness.



  3. Okechukwu
    Nov 02, 2021

    Good one

  4. Immanuel Nduri
    Mar 22, 2021

    I want a wiring licence.that’s all I want.

  5. ajugu Olatunde
    Jan 23, 2021

    I love this site come back later

  6. Jerry
    Sep 04, 2019

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  7. Sasidharan nair
    May 13, 2017

    Why i cant download your valuable pdf regading plc, electrical wiring, motor wiring etc, etc.

    • Edvard
      May 13, 2017

      What do you mean? What kind of problem you experience?

  8. Sandile Manzi
    Apr 15, 2017

    Hi, I just want to thank the site for giving me useful knowledge in electrical engineering, especially in automation. I recently qualified as a Millwright artisan and I have electrical engineering certificate from an FET college in SA. I would like to know more about PLC, up to an advanced level, but some books I have are more complicated. Would you suggest that I attend a PLC course, maybe a Siemens, from basic to advanced?

  9. John
    Feb 11, 2017

    Good job..Very good inputs here, Thank you!

  10. agustin
    Jan 18, 2016

    Good for learners

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