How do I determine what wire gauge to use?

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SUMMARY

To determine the appropriate wire gauge for a 24VDC motor drawing 50A, it is essential to select a wire rated for at least 50A to prevent overheating. For a cable length of approximately 10 feet, a wire gauge of 10mm² is recommended. It is crucial to consider insulation and proximity to other cables, as these factors can affect the wire's performance. Purchasing cable specifically rated for the required current ensures safety and reliability during operation.

PREREQUISITES
  • Understanding of electrical current ratings
  • Familiarity with wire gauge standards
  • Knowledge of insulation types and their properties
  • Basic principles of electrical safety
NEXT STEPS
  • Research "AWG wire gauge standards" for detailed specifications
  • Learn about "current carrying capacity of wires" to understand limitations
  • Explore "insulation types for electrical wiring" to ensure compatibility
  • Investigate "overheating prevention techniques" for high-current applications
USEFUL FOR

Electrical engineers, DIY enthusiasts, and anyone involved in wiring motors or high-current electrical systems will benefit from this discussion.

opmal7
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I have a motor that I am using, and I need to know what gauge wire to use to connect to the motor. I've looked all over online, but haven't found anything that can tell me a formula or anything to use to figure this out.

The motor is 24VDC and draws 50A max, and would be running about 15 mins per hour of product use. The cable length is approx 10 ft. Is there any more information required to determine what gauge wire I should use?
 
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There are tables of current handling capacity for a whole range of cable gauges, available. A google search for "Wire Gauge current rating" will yield a load of possible links.
The insulation and proximity to similar cables will have as much relevance as the simple current rating of the wire, though. For instance, drums of extension cable need to be protected from overheating when operated with most of the cable actually on the drum.
It is simpler to buy cable which is rated (on the pack) for the current that you want to use (erring on the large size if there is any doubt). That will enable you feel confident that it will not overheat. Forget about the duty cycle unless there is a serious reason for 'pushing your luck' and cutting down on cost. Just select 50A cable from a catalogue (which I expect will be 10mmsq) and then you won't need to worry. It will be annoyingly expensive but 50A is quite a heavy load (typical Electric Shower Power cable)
 

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