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Ask an Expert Forum Choosing the correct multiconductor wire size
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Choosing the correct multiconductor wire size

Former Member
Former Member over 9 years ago

I have multiple solenoid valves I want to supply control power via a multi conductor cable. Each valve draws .8 amps at 120v. I could use 22awg size wire in my cable for the wires operating each valve. My question is about the common wire. Since that wire is common to all the valves will I have to size my wire based on the current running through that wire? Am I correct in thinking that if all four solenoids were active at once then the common wire would be carrying a load of ~4 amps? (4 sol x .8 amps each) so the common wire would need to be sized at 18awg? This sounds like such a novice question I know. Any help would be appreciated!

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  • clem57
    0 clem57 over 9 years ago

    Getting Wired: How to Choose the Right Speaker Wire for Your Home Audio System is a good guide, but American Wire Gauge table and AWG Electrical Current Load Limits with skin depth frequencies and wire breaking strength gives more background.

    Here is what you need:

     

    • distance because this gives resistance that accumulates the father away on the wire.
    • thickness of wire again affects resistance.
    • Temperature affects conductance.
    • Environment: what happens if poorly shielded and a storm is overhead? This attracts a lightning strike. Protect your stuff!

     

    Clem

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  • shabaz
    0 shabaz over 9 years ago

    This sounds like a mains powered project. Could you describe it a bit more? Are the cables internal or external to the equipment?

    How far are the devices? What is the controlling equipment, and what is the use-case?

    All these will affect the answer.

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  • Robert Peter Oakes
    0 Robert Peter Oakes over 9 years ago

    As far as your basic question, you are correct

     

    4 relays consuming just under an amp each with a common return will result in 4 Amps flowing in the return wire when all are on so it must be sized to handle that load. what also needs consideration is the distance between the control point and the relay, if too far then you may need bigger gauge wire to compensate for losses in the wire

     

    You need to ensure you have protection across the load as well to protect back emf from blowing the control circuits, these may already be in the relays or the controller but make sure they exist, if not then add them (This is sometimes called a snubber network). If the Solenoids are DC then a Diode across the solenoid will work but I assume you're using AC due to being a common mains voltage, and in this case the snubber will be across the switch

    Image result for solenoid snubber network

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  • jw0752
    0 jw0752 over 9 years ago

    Hi Larry,

    Are these very large valves? I find 0.8 Amps at 120 volts ( 96Watts) quite a lot of power for a solenoid to need. I checked some specifications and a solenoid with a 20 N spring still only needs about 40 watts ( 0.33 Amps).

    John

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  • Former Member
    0 Former Member over 9 years ago in reply to shabaz

    Cable are external to the equipment. They are about 50 feet from the power source. An allen bradley PLC is controlling the equipment via output card. The use is to operate solenoid valves controlling hydraulic cylinders.

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  • Former Member
    0 Former Member over 9 years ago in reply to Robert Peter Oakes

    Thanks for the reply! The protection is built into the output cars of the allen bradley I/O rack.

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  • Former Member
    0 Former Member over 9 years ago in reply to jw0752

    Yes they are fairly large, they are part of a hydraulic system operating a very large lift.

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