Wire Requirements
Wire Sizes
Wire size is measured in American Wire Gauge (AWG). In this system, a larger number means a smaller, thinner wire — so 8 AWG is much thicker than 22 AWG.
The minimum wire size for any circuit is determined by the breaker or fuse protecting it. A wire that's too small for its breaker can overheat and start a fire.
Minimum Wire Size by Breaker
| Circuit Breaker / Fuse | Minimum Wire Size |
|---|---|
| 40 A | 12 AWG |
| 30 A | 14 AWG |
| 20 A | 18 AWG |
| 5 A | 22 AWG |
| Signal level* | 28 AWG |
| Battery and main breaker path | 8 AWG |
*Signal level circuits carry no power and cannot supply more than 1 A. Examples include robot controller I/O, CAN signals, and similar low-current lines.
Preferred Wire Size by Component
We sometimes choose wire larger than the minimum — to reduce voltage drop on high-power devices, improve durability, or standardize our stock. The table below lists preferred wire sizes for common components. Proper fusing is still required regardless of wire size.
| Component | Wire Size |
|---|---|
| Robot Controller | 18 AWG |
| Talon FX — Kraken X60 | 10 AWG |
| Talon FX — Kraken X44 | 12 AWG |
| SPARK MAX — All | 12 AWG |
| SPARK Flex — All | 12 AWG |
| Sensor power | 18 AWG |
| CAN | 22 AWG |
| LED power | 18 AWG* |
| Robot Signal Light | 22 AWG |
*18 AWG if LEDs are fed from external power. 22 AWG is acceptable if fed directly from the robot controller.
Wire Color Code
Using consistent wire colors makes the robot easier to debug and inspect — especially under time pressure at competition.
| Application | Color |
|---|---|
| +12 V | Red |
| 0 V (ground) | Black |
| CAN High | Yellow |
| CAN Low | Green |
| +6 V | Red |
| +5 V | Red |
| Signal | White* |
| Ethernet | Blue / Various |
*Other colors are acceptable when multiple signal conductors are bundled together in the same run.
Never use red or black for signal wires — a misidentified wire in a power circuit can cause immediate and hard-to-diagnose damage.