Understanding AWG and Its Impact on Industrial Ethernet Cables

The American Wire Gauge (AWG) system is a measuring system used for the size of conductors in cables—the smaller the AWG number, the thicker the conductor. For example, 24 AWG cables have thicker wires than 26 AWG or 28 AWG cables, which translates to lower electrical resistance. With low resistance, the thicker conductors will have better signal integrity over longer distances—and this is an important factor for industrial Ethernet applications.

24 AWG cables tend to have better signal characteristics, less signal attenuation, and are able to deliver more power, which can be an important factor for applications with Power over Ethernet (PoE)—and even more significant with PoE++ devices. On the contrary, 26 AWG and 28 AWG are "thinner," and as a consequence, more flexible—this is especially useful for tight spaces or shorter cable runs where the physical installation is more of a consideration than maximum distance.

The size of conductors also has an effect on heat dissipation and greater resistance to electromagnetic interference—both factors are important in any industrial environment, especially in terms of robust industrial Ethernet cables that are designed to work in heavy-industrial environments. To highlight the comparison:

Being aware of these electrical and physical characteristics will help you settle on the right AWG size for applications using CAT5e Ethernet cable, CAT6a, or OFC cabling. Making the appropriate gauge selection will result in dependable and effective power delivery and ease of installation, all of which is subject to TIA and IEEE industrial Ethernet specifications.

Industrial Ethernet Cable Types and Their Suggested AWG Sizes

Industrial Ethernet will typically fall into a few cable categories, each of which is designated for specific performance and environments. Common types of cable include CAT5e Ethernet cable, CAT6a, or oxygen-free copper (OFC) cables. These categories of cables are all differentiated through bandwidth, shielding, and conductor quality, which reflects on the gauge of the cable for the job and the application for which they are best suited.

For example, CAT5e Ethernet cable would typically be rated at 24 AWG conductors as the expense versus performance is appropriate for the common industrial application at 1 Gbps. Alternatively, CAT6a wires are generally rated at 24 AWG or 26 AWG for greater bandwidth and reduced crosstalk, and are more ideal than CAT5e cable when a high-speed application or longer-distance run has to be considered. Then there are OFC wires, known for better conductivity and clearer signals, that are typically rated similarly to CAT5e and CAT6a with a general rating of 24 AWG to aid performance in difficult industrial environments.

In industrial settings, shielding is very relevant. The main types of shielding are shielded Ethernet cables of various types, which include: STP (Shielded Twisted Pair), FTP (Foiled Twisted Pair), or S/FTP (Shielded Foiled Twisted Pair) cables. The shielded cable types generally use thicker and thus naturally will use larger conductor sizes to perform better, such as 24 AWG or 26 AWG, which will help resist electromagnetic interference (EMI). UTP cable (unshielded) tends to use thinner gauges, such as 26 AWG or 28 AWG, to perform well in a low-interference indoor setting.

Below is a summary chart to show the cable types, AWG sizes, and potential uses, as well as the general expected EMI protection level:

Selecting the appropriate AWG size and shielding configuration helps to ensure a robust level of data integrity and minimize signal loss when subjected to electrical interference, which is vital in order to support the reliability and efficiency of your industrial Ethernet network.

AWG Selection Based on Application for Industrial Use

When using industrial Ethernet, application-focused and customized cable selections are necessary to support performance limitations, along with electrical power delivery and preferences between installation requirements. The selection of AWG size based on the use of Outdoor Ethernet Cable, PoE Cable, or interconnection from M12 to M12 has a comprehensive impact on practicality, network performance, and serviceability.

If PoE++ network backbone runs are long-distance outdoor cables, we recommend using 24 AWG cable. The thickness of the conductor creates less resistance and heat build-up, allowing power to be delivered throughout the run, again, under reasonable service conditions and lengths, to upwards of one hundred meters. Note that these cables are often used in combination with industrial-rated CAT6a shielded M12 connector series or PROFINET-type cabling, which, when used together, can withstand abusive environmental conditions and excessive electromagnetic interference.

Medium-distance runs on work environment floors, factory floors, or production lines usually benefit from a 26 AWG cable. This standard size provides a reasonable balance of electrical performance and serviceability with the lengths of run necessary for industrial electrical use. This size of cable can also be used in conjunction with M12 4-pin or 8-pin connectors or cable connection types (M12) related to M12 A-coded connectors, M12 D-coded connectors, or M12 X-coded connectors. These issues can easily be addressed while beneficially using a 26 AWG cable to transmit reliable data and moderate PoE loads, all while considering cost aspects that would not detract from performance.

28 AWG cables provide excellent overall performance, especially in potentially interfaced or congested conditions, where the small size and flexible cable type will allow for movement. You will find these cables in areas like cabinets, closets, or patch panels where space is limited, and shorter runs need to be performed. As noted, they will not be able to hold the same degree of performance under electrical power use as the thicker AWG cables do, but when intended to be used as service or connection points for density with maneuvering cable sections, they can perform.

Key Recommendations:

• 24 AWG: Long runs outdoors and shielded cabling, PoE loads for heavy electrical use.
• 26 AWG: Mid-distance cabling with cost considerations for performance.
• 28 AWG: Short-distance cabling for patch cable use and flexible usage in cabling management.

The appropriate use of conductors, along with the appropriate shielding, connectors, and standards for electrical service (M12, etc.), all contribute to robust networks that can adapt to the conditions of operational needs and the challenges of the industrial environment.

Comparative Chart with Detail: 24 AWG vs 26 AWG vs 28 AWG for Industrial Ethernet

Wide selections of the industrial Ethernet cable gauge matter in making parallels of usage with industry-related products for connection with telecommunication products, i.e., CAT5e or CAT6. The following comparison chart illustrates key technical (performance) and practical differences by category position.

This comprehensive comparison lays out the performance vs. flexibility and cost trade-offs. As an example, a 24 AWG CAT6 shielded cable is great for long-distance, high-powered PoE installations, while 28 AWG patch cables are fantastic for flexible, shorter-distance patch runs inside control cabinets or racks. By selecting the proper AWG and shielding, using options like 24 AWG, gives you a strong, reliable industrial Ethernet network infrastructure.

This table helps further explore some of the related specifications needed for cable selection in an industrial environment without further reference to previously stated technical explanations.

FAQs

What are PoE++ requirements for AWG cables?
PoE (802.3bt) relies on lower resistance cables to deliver more power safely. Typically, 24 AWG cables accommodate PoE++, while 26 AWG may also be fine with a moderate load. 28 AWG is generally not used for heavy PoE devices because of increased resistance and heating.

Can 28 AWG cables support 10Gbps speeds?
Yes, many well-made CAT6a 28 AWG patch cables can achieve 10Gbps data rates at average distances under 100 meters using the complicated manufacturing process and improvement of shielding throughout the cable. However, they are generally used for shorter or flexible patch runs.

How do AWG differences affect cable flexibility and installation?
Smaller AWG numbers (thicker wires) will tend to result in decreased flexibility and bulkier cables with more difficult routing. 28 AWG cable is significantly more flexible, which is ideal for dense or indoor cabinets and racks, while 24 AWG is stiffer, making it more appropriate for longer and higher-performance runs.

What are the AWG differences in CAT5, CAT5e, and CAT6?
As a convention, CAT5e and CAT6 cables commonly use 24 AWG for backbone runs, which provide stable high-speed connectivity. However, some slim and flexible patch cables may also utilize 26 or 28 AWG cables to gain performance while saving space and weight.

These practical responses clarify operationally driven choices related to minimum AWGs without redundancy of the keywords.

New Standards, New Technologies, and Their Role in AWG Selection

Recent advancements in industrial Ethernet standards have impacted how cable gauge selection aligns with changing network criteria. One such new standard is IEEE 802.3bt, commonly referred to as PoE++, which has increased power supplied to PoE from 32W to nearly 100W, a threefold increase! Increased power demands lead to the consideration of thicker conductors, such as 24 AWG, which can help reduce opposition and heating of conductors when powering devices over Ethernet. 28 AWG conductors typically cannot support these higher PoE levels safely while still maintaining performance requirements.

The other part of the standards evolution is Single Pair Ethernet (SPE), which provides a different type of cabling solution for constrained size and cost by moving away from four-pair conductor specifications. This presents an opportunity to think through the AWG size in some industrial applications where weight and space need to be considered.

Some other considerations are associated with shielding technology as a method for reducing electromagnetic interference (EMI) and possibly increasing security. The type of cable—STP, FTP, S/FTP, or other types of shielding—allows for different levels of protection. For example, CAT6a shielded cables and M12 X-coded connectors will limit EMI in many industrial environments. All types of shielding and standards can limit or eliminate interference issues, including reducing cyber intrusion in some industrial settings.

Also, industrial connectors like the M12 A, D, and X-coded connectors may also dictate gauge size connectors since the physical and electrical properties of these cables are crucial. Therefore, even in nondescript AWG applications like considering single-pair and multi-pair cables, the physical and electrical criteria often dictate the selection to guarantee connector life and signal integrity.

A similar consideration is often a compliance aspect like Advanced Physical Layer (APL), which sets maximum lengths and insertion loss. This is potentially beneficial for people using industrial networks. Overall, in their totality, these technologies and standards now play a key role in determining selected AWG sizes when considering power needs for industrial cables, signal requirements, and what is required in the harsh environments of many cabling applications.

In practice, some vendors may leverage these standards to apply cabling technologies and solutions that comply with the potential consequences of modern industrial solutions.

Conclusion

Selecting the appropriate AWG size is critical to various industrial Ethernet applications to help ensure performance, signal quality, power, and ease of installation. For distant, typically high-power PoE applications, 24 AWG works in all metrics. 26 AWG balances cost vs. performance for any relatively standard industrial use. 28 AWG fits flexible needs and is installed in spaces designed to carry signals in its own right, such as manufacturing. Don’t underestimate the benefit and value of appropriate AWG sizes in conjunction with standards that consider power, signal, and the environment for manufacturers, suppliers, and installers.