Does anyone know the required wire gauge needed to run from a relay to a switch and back to the relay? This is my idea, but i dont know if the wiring is going to be thick enough.... So im going to be running a few misc. switches to various things around my jeep and i was thinking that it would be a lot easier to run 1 CAT 5 cable (it has 4 pairs of twisted wires (8) wires total) from the switch section to the relays. This way it keeps all the wires together, you only have to drill ONE SMALL whole, and there all color coded so its easier match the switches to relays. The CAT 5 is 24 gauge but i dont know if thats going to be big enough, even though it has almost NO current going through it because its just telling the relay to kick on and all the current goes through that. Has anyone done this or thought about doing this?

Thanks

 

It really depends on the relays (different relays will have different current draws) -- although I'd probably not really consider running 12v across Cat5...

I'd probably consider something like the following wire:
4 conductor -- http://www.lowvoltagewire.com/produc...d=104&catid=36
6 conductor -- http://www.lowvoltagewire.com/produc...d=141&catid=36

(I'm not affiliated with this vendor in any way and have not even purchased wire from them. I'm sure you could source similar wire from the vendor of your choice)

The six conductor wire is shielded, but that shouldn't matter.

You only need to run one conductor from each switch to its related relay, so if 4 relays would be enough, the 4 conductor will be sufficient.

If you get creative and wire the relays and switches following this diagram, you won't eve have to find a hot lead to connect the switches to -- all you have to do is find a good ground.



This will also work for illuminated switches -- it's just important to remember that the positive lead needs to be connected to the relay.

If you have questions feel free to PM me.

--Sky

 

The ampacity of an insulated AWG 24 conductor is listed at between 2.0 and 4.0 Amps (depending upon the whose table you use) at 25 C. This is derated by 80% at 150C. So the cable should work fine! Terminating 24 gauge wire, especially in a harsh environment, can be a bear! Typical stranded 24 has 7 strands, so cut one while striping and you have lost 14% capacity!

I am actually doing something similar with two distribution panels, one in the rear and one front. Nothing to shout about yet, but I will post when done.