Hall sensor body leads out a single core wire (core supply section of electronic wire factory)
The single core thin wire between the packaged sensor and the connector/main control board has a very small current (signal+power+ground), and the wire diameter is mainly determined by mechanical strength and voltage drop. The mainstream is 22-26AWG (0.14-0.34 mm ²), and the power supply end can be placed at 20-22AWG.
1. Normal temperature environment (consumer electronics, home appliances, power tools, small brushless motors)
| Standard/Model | Insulation material temperature | Degree/Voltage | Typical uses | Common specifications |
| UL1007 | PVC | 80℃ / 300V | Hall signal line, power line, ground line, most universalHall signal line, power line, ground line, most universal | 22AWG (0.34),24AWG (0.2),26/28AWG |
| UL1061 | SRPVC semi-rigid PVC | 80℃ / 300V | Signal flying wire inside the board, with good mechanical stiffness | 22/24AWG |
| UL1015 | PVC | 105℃ / 600V | Signal circuit with slightly higher temperature resistance | 22/24AWG |
| UL1569 | PVC | 105℃ / 300V | Signal lines in areas with high temperature rise | 22/24AWG |
| UL10493 | PP | 80℃ / 300V | M8/M12 sensor output line (commonly used in Weidmuller and other solutions) | 0.34 mm² |
The Hall component of a brushless motor has a total of 5 wires: 1 power (red), 1 ground (black), and 3 U/V/W position signals (yellow/green/blue). The Hall signal lead from the controller to the motor is generally AWG24 (AWG26/28 for small motors, UL1007); Note that three-phase power wires (AWG18 and other thick wires) do not belong to Hall wires and must be quoted and selected separately.
2. High temperature/oil/chemical resistant environment (engine compartment, industrial equipment, close to heat sources)
| Material/Model Direction | Temperature resistance level | Applicable scenarios |
| Radiation cross-linked XLPE (such as UL3173, 125 ℃ AWM) | 125℃ / 300V,VW-1 | Outdoor, vibration, and oily environments, with better aging resistance than ordinary PVC |
| Silicone wire/AGR silicone wire | 180-200℃, extremely soft and vibration resistant | Close connection near the motor, heat source, and engine compartment |
| FEP/PTFE (Teflon) insulated wire, YGZF class | Above 200℃ | Sensor leads that are resistant to high temperatures, oil, and strong corrosive chemical media, with a very fine outer diameter |
| Nylon multifilament (poly nylon, such as Lake Shore laboratory probes) | High precision at room temperature | Precision magnetic field measurement probe inner lead, 34AWG copper lead; Its high-temperature model uses Teflon (FEP/PTFE) insulation |
3. External multi-core/shielded connection cable (sensor → controller/instrument)
When there is interference from motors, frequency converters, ignition systems, etc. during medium to long distance transmission, single core wires are insufficient, and multi-core sheathed wires and shielded cables are required.
1)Unshielded multi-core component wire
UL2464 (PVC multi-core sheathed electronic wire, 80℃/300V): 4/5/6-core combination motor Hall harness, core wire 22-24AWG.
2)Shielded signal/instrument cables (mainstream category)
| Type | Structure/Specifications | Typical Applications |
| European standard LiYCY (LiYY unshielded) | PVC insulation+PVC sheath, aluminum foil+tinned copper braided shielding, 2/3/4 cores, 0.14/0.25/0.34/0.5 mm², wire core according to DIN 47100 color code | Industrial Hall proximity switch, speed/steering sensor, Hall transmitter |
| American standard shielded instrument cable | Belden 8761 (2-core), 8771 (3-core), 8723 (4-core), 22AWG stranded tinned copper+foil/braided shielding, equivalent to domestically produced shielding wire | Long distance signals from Hall sensors for speed and position |
| Automotive Hall Speed/Camshaft Position Sensor Wiring Harness | 3-core dual shielding (power+signal+ground), 22AWG multi strand tinned copper, with built-in shielded ground wire; Nitrile rubber/PUR oil resistant sheath, wide temperature range -40-125℃ (partially up to 150℃), resistant to engine ignition high pressure interference | Engine compartment speed, vehicle speed, crankshaft/camshaft position detection |
| Hall current sensor (open-loop/closed-loop) cable | The power supply line and output signal line use 0.5 mm² shielded wire, and it is prohibited to wire them in the same slot as the power line; Use twisted pair shielded wires in environments with 10-50m or strong interference, with a shielding coverage rate of ≥ 85%; The primary high current busbar/wire does not belong to the signal electronic line | Variable frequency drive UPS, Inverter, photovoltaic energy storage, distribution current detection |
| High flexibility drag chain/robot occasions | PUR sheath, aluminum foil+braided double shielding, multi strand fine copper wire, such as JZ-500 high flexibility sensor control cable | Equipment with repeated bending and dynamic wiring |
4. Color convention for wires (reference for wiring and harness color matching)
Three wire Hall switch/linear Hall
VCC red, GND black (some European and American systems use blue), OUT green/white/yellow.
Brushless motor 5-core Hall
Red=power, black=ground, yellow/green/blue=U/V/W position signal.
Four wire discrete Hall chip
Controls the current to be extremely red, and outputs the Hall voltage to be extremely green.
European standard sensor cable cores
Comply with DIN 47100 (brown, blue, white, green, yellow, etc.).
5. Quick selection check (material selection by scene)
| Application Scenarios | Recommended electronic cable category | Common specifications |
| In board/short distance signal, room temperature | UL1007, UL1061 (UL1015/1569 if necessary) | 22–26AWG |
| Outdoor, vibration, oil pollution, 125℃ | Radiation XLPE (UL3173 class) | 22-24AWG signal/14-18AWG power (non Hall) |
| Near heat source, 180-200℃ | Silicone/AGR silicone wire | Approximately 22AWG |
| High temperature resistance, oil resistance, and chemical resistance | FEP/PTFE/ETFE insulated wire | 22–26AWG |
| Complete set of Hall wire harness for motor | UL2464 multi-core sheathed wire | 4/5/6 cores x 22-24AWG |
| Industrial long-distance, anti-interference | LiYCY/shielded instrument cable (twisted pair optional) | 2/3/4 cores x 0.14-0.5 mm ² (18-22AWG) |
| Engine compartment automotive sensors | Double shielded tinned copper wire+oil resistant nitrile/PUR sheath | 3-core x 22AWG |
| Hall current sensor | Shielded wire/twisted pair shielded wire | 0.5 mm² signal power supply |
Summary in one sentence: The chip has gold/aluminum wire bonding and metal pins inside, which does not require electronic wiring; The opportunities for using electronic wires are concentrated in two sections - single core signal wires inside the board/body (UL1007/1061/1015/1569, 22-26AWG, high temperature section using XLPE, silicone, etc.) FEP), And external multi-core shielded wire harnesses (UL2464, LiYCY, Belden type instrument shielded wire, automotive double shielded oil resistant wire)
