Everything You Need to Know About Electrical Wires and Connectors in FPV Drones

In FPV drones, the electrical wiring and connectors play a crucial role in ensuring that the drone operates efficiently and safely. In this tutorial, we will cover everything you need to know about electrical wires and connectors, including the different types and how the size of wire and connector affects performance.

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What Type of Electrical Wires Should You Use for Your FPV Drone?

There are several types of wires available, the most common type used in FPV drones is silicone stranded wire. Compared to solid core wires, stranded wires are more flexible and easier to work with.

Compared to PVC-insulated wires, Silicone-insulated wire is preferred for RC applications due to its flexibility, especially as multirotor frames and components continue to shrink in size. Silicone wires are also lightweight and can tolerate a wider temperature range, making them more durable in extreme environments. In addition, they are less likely to melt or shrink when exposed to heat during soldering.

Electrical Resistance in Wires

One important factor to consider when choosing wires for your FPV drone is the wire’s resistance. Longer or thinner wires will have more resistance, which can lead to voltage drop and power loss (especially so for the battery). This is why wires have a current rating.

To minimize resistance, it’s best to keep your wires as short as possible. While thicker wires can also help reduce resistance, they can add weight to your drone.

To ensure that your power system can deliver the required power, make sure your wires are appropriately sized for the components in your drone. Choosing the right size wire will prevent it from becoming a bottleneck in your power system and allow your drone to perform at its best.

Understanding Wire Gauge

Wire gauge refers to the thickness of the electrical wire and is measured in AWG (American Wire Gauge). Choosing the right wire gauge is important to ensure that the wire can handle the current required by the component it is connected to.

In general, the higher the AWG number, the thinner the wire. The lower the AWG number, the bigger the cable size and current capacity. The current rating of a wire is the maximum amount of current that it can safely handle without overheating or becoming damaged.

When building an FPV drone, minimizing weight is important. For instance, here are some commonly used wire gauges for different components on a 6S 5-inch FPV drone:

• 14AWG for Battery XT60 Pigtail
• 18AWG-20AWG for ESC and Motor power wires
• 28AWG for other low power components and signals

When connecting two wires, the maximum current that can be passed through them is limited by the smaller wire. Therefore, if you are extending a wire, it’s best to match the wire gauge and use the same AWG wire. Using larger wires than necessary doesn’t provide any benefit but extra weight, which is not ideal for an aircraft.

Here’s the estimated weight per meter of wire for different AWG number:

• 24 AWG – 4.5g
• 20 AWG – 7.5g
• 18 AWG – 11g
• 16 AWG – 20g
• 14 AWG – 27g
• 12 AWG – 39g
• 10 AWG – 61g

Disclaimer: The numbers in this post are a guide only.

Current Rating Look-Up Table

To determine what AWG wires you need, you should first work out your quad’s maximum amp draw and then refer to a current rating look-up table. The current rating is normally a continuous current if not specified.

Different electrical wire manufacturers may have different standards and current ratings. Here’s one example:

Example – Wire AWG and Current ratings

As a general guideline, I personally follow this table based on the burst current requirement (e.g. current draw at full throttle):

• 10AWG Wire: 250A
• 12AWG Wire: 160A
• 14AWG Wire: 110A
• 16AWG Wire: 80A
• 18AWG Wire: 50A
• 20AWG Wire: 30A
• 22AWG Wire: 24A
• 24AWG Wire: 20A

It’s important to use the appropriate wire size to minimize voltage drop and power loss due to resistance, and to reduce the risk of overheating. However, in some cases, it may be acceptable to use slightly thinner wires if the wire length is short and the current bursts are only for a short period of time to minimize weight.

In my 6S 5″ builds, I usually use 14 AWG wires for connecting the battery, even though the maximum current draw might be slightly over the current rating of the 14AWG wire. I don’t think this would be a problem because, firstly the wires are quite short; secondly, the current bursts typically only lasts for a couple of seconds, even if you leave it at full throttle for longer, the battery wouldn’t be able to keep up anyway. The main reason I prefer 14AWG over 12AWG is because they are easier to solder to the ESC, and can shave a couple of grams off my build.

There’s also voltage rating for electrical wires, but it’s usually not a concern for RC applications, since the voltage we are dealing with are well below 30V. The wires we use can tolerate much higher voltage (e.g. hundreds of volts or even higher).

Where to Buy Silicon Electrical Wires

Are Red and Black Wires Different?

No, red and black wires are the same wires, just different in colour. You can use any colour wire you want for your drone, but conventionally, red is used for positive power and black is used for ground. Following this convention makes it easier to visualize which wire is which and helps prevent mistakes. There are other colour-coded wires which are typically for signals, but it’s totally up to you what color wires to use.

12 AWG

Applications: For XT60 pigtail, high power 5″, 6″, 7″ FPV Drone.

• AliExpress: https://s.click.aliexpress.com/e/_DlSpVMh
• Amazon: https://amzn.to/3JcFN5H
• Banggood: http://bit.ly/2ALByxa
• GetFPV: https://oscarliang.com/product-bt0a
• RDQ: https://oscarliang.com/product-wj65

14 AWG

Application: for XT60 pigtail, medium power 5″ FPV Drone.

• AliExpress: https://s.click.aliexpress.com/e/_DEWmXTR
• Amazon: https://amzn.to/3JvxFi1
• Banggood: http://bit.ly/2ALByxa
• GetFPV: GetFPV
• RDQ: https://oscarliang.com/product-wj65

16 AWG

Application: for XT30 and XT60 pigtail, long range builds (80A burst).

• AliExpress: https://s.click.aliexpress.com/e/_DFtzaZX
• Amazon: https://amzn.to/3Jfu0DE
• Banggood: http://bit.ly/2ALByxa
• GetFPV: https://oscarliang.com/product-z3it
• RDQ: https://oscarliang.com/product-wj65

20 AWG

Application: for XT30 on sub250 builds, and motor wire extension for 5″ builds. 18AWG also works well if you don’t mind the slight extra weight.

• AliExpress: https://s.click.aliexpress.com/e/_Dk5DjAZ
• Amazon: https://amzn.to/3UoSSOH
• Banggood: http://bit.ly/2ALByxa
• GetFPV: https://oscarliang.com/product-jc8f
• RDQ: https://oscarliang.com/product-wj65

26AWG-28AWG

Application: for signals, power for your FPV system, receiver etc, basically anything that isn’t battery or motor related.

• AliExpress: https://s.click.aliexpress.com/e/_Deft3NF
• Amazon: https://bit.ly/3LkxHuE
• Banggood: http://bit.ly/2ALByxa
• GetFPV: https://oscarliang.com/product-qzda

Choosing the Right Connectors for Your FPV Drone

Connectors are an essential component for attaching two components temporally, such as the battery and ESC. You can also use connectors if you don’t like soldering.

For signals, it’s less of a problem and you can use any connector you want. However, when it comes to battery or any high current applications, it’s crucial to choose the right type of connector, because like wires, connectors also have a current limitation.

Here is a general guideline for the continuous and burst current ratings of some commonly used connectors:

• JST connector: 5A (10A)
• 2mm bullet connectors: 20A (40A)
• XT30: 30A (60A)
• XT60: 60A (180A)

While it’s tempting to overcompensate and use larger connectors, it’s not always necessary and can add unnecessary weight to your drone. In some cases, it may even have a negative impact on your drone’s performance. For example, when it comes to micro drones such as Tiny Whoops, there’s a debate about whether XT30 connectors or BT2.0 / A30 connectors are the better option. While XT30 connectors have a lower resistance than PH2.0, BT2.0 and A30, but the benefits are hardly noticeable while it’s much heavier, some argue that BT2.0 and A30 are the optimal choices because they provide a good compromise between weight and performance. You can learn more about these connectors for micro drones in my testing: https://oscarliang.com/micro-battery-connectors-testing/

By choosing the appropriate connector based on your drone’s specific needs, you can ensure that your drone operates safely and efficiently.

Where to Buy LiPo Battery Connectors

Two of the most popular battery connectors used in FPV drones are the XT60 and XT30 connectors. These connectors share the same design but come in different sizes and are rated for different maximum currents. According to the official datasheet, the XT60 connector is rated for a maximum current of 60 amps, while the XT30 connector is rated for a maximum current of 30 amps. These ratings are designed to ensure safe operation of the connectors under specific conditions.

However, recent test has shown that the XT30 connector can actually support a much higher continuous current of up to 60 amps without any problems, as long as the wires connected to it are large enough. This means that you can safely use an XT30 connector for applications that require higher currents, as long as you follow the appropriate safety precautions.

On the other hand, the XT60 connector has also been put to the test, and it has been found that it can safely handle burst currents of up to 180 amps for 10 seconds without any problems. This makes it a reliable choice for a typical FPV drones without the need to upgrade to heavier and bulkier connectors.

XT60 Connectors

• RDQ: https://oscarliang.com/product-xzn1
• GetFPV: https://oscarliang.com/product-hwx7
• Amazon: https://amzn.to/3l6oonc
• Banggood: http://bit.ly/2AuxHnC
• AliExpress: https://s.click.aliexpress.com/e/_Ddy57H7

XT60 14AWG Pigtail

Comes with wires soldered on.

• AliExpress: https://s.click.aliexpress.com/e/_DdHrwIp
• Amazon: https://amzn.to/403AkVQ
• Banggood: https://oscarliang.com/product-06wq
• GetFPV (12awg): https://oscarliang.com/product-4bun
• GetFPV (16awg): https://oscarliang.com/product-a8nh
• RDQ: https://oscarliang.com/product-l0p0

XT30 Connectors

• RDQ: https://oscarliang.com/product-6gvi
• GetFPV: https://oscarliang.com/product-0ipn
• Amazon: Amazonhttps://amzn.to/3l8PdY0
• Banggood: http://bit.ly/2zTIRD6
• AliExpress: https://s.click.aliexpress.com/e/_DkJfemp

XT30 16AWG Pigtail

Comes with wires soldered on.

• AliExpress: https://s.click.aliexpress.com/e/_DkQ06hP
• GetFPV: https://oscarliang.com/product-d6t7
• Amazon: Amazonhttps://amzn.to/3yvHtSU
• RDQ: https://oscarliang.com/product-aq6b

Tips for Using Wires and Connectors

What Gauge Wires for Extending Capacitor?

When extending a capacitor in your FPV drone, the recommended wire gauge will depend on the size of the capacitor and the amount of current it will be handling. But in general, the length of the wires are more important than the wire gauge.

For smaller capacitors (under 1000uF), you can use thinner wires such as 18AWG or 20AWG (like the motor wires). For larger capacitors (over 1000uF), it’s best to use thicker wires such as 16AWG. It’s important to keep the wire as short as possible to minimize resistance.

You can learn more about why and how to add capacitor in your drone in this article.

Soldering Techniques

Proper soldering techniques are important for creating strong, reliable electrical connections in your drone. Techniques for soldering wires and connectors include tinning, splicing, and using heat shrink tubing to protect the connection. It is important to avoid common soldering mistakes such as overheating the wire, creating cold joints, or using too much solder.

You can learn about how to solder wires and connectors in this tutorial.

Proper Cable Management

When routing wires in your drone, it’s important to keep them as short as possible to reduce the risk of interference and voltage drops. If the wires are too long, you can twist them to keep them neat and tidy, which also help against interference.

When connecting wires and components, ensure that they are securely fastened and will not come loose during flight. Loose wires can cause significant damage to your drone during flight and potentially lead to a crash.

It’s also important to avoid resting cables on top of the flight controller, apart from potentially causing interference, it could also be hitting the gyro which affect flight performance. Instead, try to route cables underneath or around the FC.

Finally, to help prevent damage to your battery lead solder joints during crashes, it’s recommended to secure the battery lead to the frame using zip ties. This provides stress relief and prevents pulling the solder joints during a crash.

More Info and Discussion

We have a similar topics on the forum if you’d like to learn more about this subject and like to comment.

Edit History

• May 2014 – Article created
• Apr 2017 – Article revised
• Nov 2017 – Added product shopping options
• Mar 2023 – Updated guide, added “Tips” section, updated product links, changed page URL