Wire bundles should be less than how many wires?

• A. 60 wires
• B. 90 wires
• C. 75 wires
• D. 120 wires

Answer: (C)

Wire bundles are groups of insulated conductors tied together, and there’s a heat-management limit to how many wires can share a single bundle. Each conductor carries current and generates heat; when many of them are bundled tightly, heat builds up and the insulation can overheat, degrade, or be damaged. To keep temperature rise within the insulation’s rating and maintain reliability, a common guideline is to limit a single bundle to 75 conductors. If more conductors are needed in the same area, split them into two or more bundles or route them separately so each bundle stays within the limit. Count all conductors inside the bundle; wires that leave the bundle aren’t included in that bundle’s total.