Solenoids are widely used in everyday applications due to their simplicity and reliability. Wiring is straightforward, but choosing the correct solenoid and control circuit is critical to avoid inefficiency, failure, or danger. The solenoid coil only requires two wires for power, but a control circuit is needed to energize and de-energize it. The solenoid must be rated appropriately for the workload and environment to prevent damage or hazards.
Solenoids are probably one of the most common sources of reliable and efficient remote actuation available and are used in an almost endless list of everyday applications. Part of the appeal of using them is the relative simplicity of wiring and installing the solenoid, with few existing restrictions and rules of thumb. Solenoids can be installed successfully if adequate power is available, the correct type of wiring is used, and the manufacturer’s connection instructions are followed. The control section of the solenoid wiring is typically the most complex part of the circuit and, if not already there, may require some careful planning and a degree of electrical knowledge. Choosing the correct solenoid for the particular application is also critical and can, if not carefully considered, result in reduced efficiency, solenoid failure or dangerous operating conditions.
Virtually every area of industrial, home and hobby business features at least a solenoid or two. These little electromagnetic workhorses deliver millions of duty cycles in a wide variety of applications and industries. They are particularly attractive in their role as remote actuators, at least in part for their latent simplicity. Solenoid wiring is typically a simple two-wire system consisting of supply and return wires connected to the solenoid coil, interrupted at some point by a control circuit activating mechanism. If a few basic principles are followed, solenoid wiring is not complicated and can be successfully installed by people with little or no electrical knowledge.
A solenoid consists of a single electrical component, namely its coil. The coil only requires the connection of two wires running to the live and neutral points of the supply in the case of an alternating current (AC) solenoid or to the positive and negative points of a direct current (DC) example. This will basically supply the electrical current needed to energize the coil and activate the solenoid and only requires the wires to be of the correct current, the correct temperature rating and of sufficient length. It is also recommended that users always follow the manufacturer’s connection instructions carefully. Of course, it is generally not desirable for the solenoid to have power all the time, so some sort of control circuit must be incorporated into the wiring to the solenoid.
Typically, the major component of the control section of any solenoid wiring configuration is a simple open and closed contact or switch. This could be a simple button, the normally open contact of a relay, or part of a more sophisticated programmable controller, and could also include timer or interlocking functions. If the solenoid installation is a new project, it will require some degree of electrical knowledge to plan and construct this part of the circuit. If the solenoid is a replacement in an existing installation, the only work normally required is to reconnect the coil. In simplistic terms, however, all the control circuit does is energize and de-energize the coil as required.
One of the most important factors to consider when approaching a solenoid wiring job is the rating of the solenoid itself. The solenoid should be large enough to handle the workload involved, with a slight overcapacity to ensure longevity of the equipment. The coil must also be suitable for the supply, and vice versa, both in terms of voltage and AC/DC rating to avoid possible damage or destruction of both the solenoid and its actuated mechanism. When the solenoid is to be installed in a hazardous environment, such as in explosive atmospheres, a suitable explosion-proof solenoid must be used to prevent explosion or fire.
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