24V Linear Actuator Wiring Guide: How to Wire DC Safely

You wire a 24V linear actuator by feeding 24V DC from a correctly sized power supply through a reversing switch, relay, or controller that swaps the 2 motor leads. Size the supply for the actuator current plus headroom, fuse the positive lead, and use wire large enough to keep voltage drop low over the full cable run.

What is 24V linear actuator wiring?

24V linear actuator wiring connects a 24V DC supply to an actuator motor so the rod extends and retracts. A switch, relay, or controller swaps positive and negative on the 2 motor wires to change direction.

Simple Explanation

Think of the actuator like a DC motor with a screw attached. Send positive to 1 motor wire and negative to the other, and the rod moves 1 way. Swap those 2 wires, and the rod moves the other way.

Use the formula below to calculate minimum 24V DC power supply current.

I_supply = I_run × N × H

When do you need 24V linear actuator wiring?

You need this wiring plan when a bench test turns into a real lift, hatch, slide, door, or machine guard. The actuator may move fine with short test leads, then slow down or trip the supply once you add 15 ft (4.6 m) of cable, a switch, and 2 actuators.

You use this calculation to choose the power supply, switch contacts, relay capacity, fuse size, and wire gauge before you cut holes in the project. If you still need to choose voltage, read Choosing the Right Voltage for Your Linear Actuator.

Suitable Applications

24V wiring works well when current matters. Longer wire runs, 2-actuator lifts, and control boxes all benefit from lower current than an equivalent 12V system.

Where do engineers and DIYers use this wiring?

• RV slide-outs, lift beds, and storage hatches that run from a DC power system.
• Robotics fixtures that need 24V DC motor power and separate signal wiring.
• CNC machine doors, guards, and chip shields tied into a control cabinet.
• Automotive prototypes, hood lifts, active aero test rigs, and service panels.
• Adjustable workstations, cabinet lifts, and inspection equipment.

For project sizing before wiring, use the linear actuator selector and the linear actuator calculator.

How does a 24V actuator circuit work?

A 24V DC supply feeds a fuse, then a reversing device, then the 2 actuator motor leads. The reversing device can use a DPDT momentary switch, relay wiring, or a DC motor controller. It does the same basic job: it swaps positive and negative at the actuator.

At the same output power, 24V pulls about 50% of the current that a 12V system pulls. A 120 W load pulls about 5 A at 24V before losses; a 12V version pulls about 10 A. Lower current reduces voltage drop and wire heating, but it does not fix a weak supply, bad geometry, or an undersized actuator.

Which current number should drive each wiring choice?

Do not use 1 current value for every part. Supply sizing, voltage drop, and protection each care about a different current event.

If the datasheet gives only running current, add headroom and test the final machine under the worst load. For supply sizing help, see Choosing the correct power supply for your application and the Power Supply Sizing Calculator.

How do you wire the switch, relay, or controller?

For 1 actuator and local control, a DC-rated DPDT momentary rocker switch gives the simplest wiring. The switch must carry the actuator motor current, not just the signal current printed on small panel switches.

For higher current, long switch runs, remote controls, or logic control, use relays or an actuator controller so the motor current does not travel through a small user switch. For controller selection, use Linear Actuator Controller Buying Guide: How to Choose Yours, actuator controls, and the wiring diagram generator.

If your load needs a relay, read High Current Linear Actuator Relay Guide: Wiring and Sizing. If you need multiple actuators to move together, read How to Synchronize Four Linear Actuators Guide: Wiring Setup.

How do you size wire and fuse for 24V?

Choose wire from voltage drop first, then check ampacity. A wire that looks safe by ampacity alone can still drop too much voltage and make the actuator slow or unreliable.

Use the formula below to calculate voltage drop in a 2-conductor DC actuator circuit.

V_drop = 2 × L × I × R_wire

Keep voltage drop under about 5% of 24V, which gives 1.2 V. Use 3% when speed consistency matters or the cable run grows long. For a quick check, use the 24V Wire Size Interactive Calculator.

A fuse protects the wire. Put it on the positive lead close to the supply. Choose a fuse above normal running current, allow for startup surge, and keep it below what the wire and controller can safely carry. For protection strategy, read Fuses vs Current Sensors: Protecting Actuator Systems.

How do you size the 24V power supply with the calculator?

Use this calculator after you know the running current for each actuator and how many actuators move together. It gives a supply current target with headroom, but it does not replace startup current, stall current, duty cycle, or controller thermal checks.

How do you use this calculator?

1. Enter the actuator running current in amps.
2. Enter the number of actuators that move at the same time.
3. Enter a headroom factor, such as 1.25 for normal projects or 1.5 for hard starts.
4. Click Calculate to see your result.

Simple Example

Given: 1 actuator draws 4 A while moving a cabinet lid.

Calculation: I_supply = 4 A × 1 × 1.25.

Result: choose at least a 5 A, 24V DC supply, then check startup surge and fuse behavior on the finished mechanism.

How do you calculate wiring for a 2-actuator hatch lift?

Let us wire a 24V hatch lift with 2 actuators. Each actuator draws 5 A while lifting the hatch. Both actuators move together. The supply sits 18 ft (5.5 m) from the actuators. You want a normal 1.25 headroom factor.

Supply current: I_supply = 5 A × 2 × 1.25 = 12.5 A. Choose at least a 15 A, 24V DC supply, then confirm startup current and duty cycle.

Now check voltage drop with 16 AWG copper at about 0.00402 Ω/ft. Total running current through the feeder equals 10 A.

Voltage drop: V_drop = 2 × 18 ft × 10 A × 0.00402 Ω/ft = 1.45 V. That equals about 6.0% of 24V, so 16 AWG runs too close to the edge.

Move to 14 AWG copper at about 0.00253 Ω/ft. V_drop = 2 × 18 ft × 10 A × 0.00253 Ω/ft = 0.91 V. That gives about 3.8%, which suits this lift much better.

This method gives better wiring than a generic chart because it separates 3 jobs: running current for voltage drop, headroom current for supply sizing, and stall or jam current for protection.

What trade-offs matter with 24V actuator wiring?

For 12V comparison wiring, see 12V Linear Actuator Wiring Guide: How to Wire DC Power Safely. For general diagrams, see Linear Actuator Wiring Diagram Guide: How to Wire 12V DC.

Related FIRGELLI Products

Use these actuator families as starting points, then confirm the voltage option, current draw, controller match, brackets, and duty cycle on the product page before you wire the system.

The Utility Linear Actuator lists Hall Effect feedback. A Hall sensor reads alternating magnetic poles on a rotating disk in the gearbox; it does not measure direct rod travel. From a controller point of view, Hall and optical feedback usually act like pulse signals, so compatibility depends on voltage, wiring, pulse type, pulse count, direction handling, and calibration.

The Utility Linear Actuator also lists MB1-P for the base end, MB1 for the rod end, and MB2 as a mounting bracket option. Mounting still drives current draw. Side load, binding, and poor pivot geometry make any 24V wiring job look worse than it really should.

Which related guides help with the wiring details?

If the circuit still feels unclear, start with the wiring diagram generator. Then use the relay, fuse, controller, wire size, and power supply guides linked above to check each part of the system before you connect power.

FAQ

Can I run a 24V linear actuator from a 12V battery?

No. A 12V battery will not supply the voltage the 24V motor needs. The actuator may move slowly, stall under load, or fail to start. Use a 24V battery pack, a 24V DC supply, or a DC boost converter that can handle running current, startup current, and duty cycle.

How do I reverse a 24V linear actuator?

Reverse the 2 motor leads. If red gets positive and black gets negative, the actuator moves 1 direction. Swap them and it moves the other direction. Use a DC-rated DPDT switch, a relay reversing circuit, or a compatible actuator controller. Do not short the supply while switching.

What size power supply do I need for a 24V actuator?

Add the running current for every actuator that moves at the same time, then multiply by at least 1.25. Use 1.5 when the load starts hard, the cable run gets long, or the actuator works in cold conditions. Then check startup current, stall current, and controller limits.

What wire gauge should I use for 24V actuator wiring?

Choose wire from voltage drop, not just ampacity. Keep voltage drop under about 5% for most actuator wiring, or 3% when speed consistency matters. Use the full 2-conductor path in the calculation, because current travels out to the actuator and back to the supply.

Do I need a fuse on a 24V linear actuator?

Yes. Put the fuse on the positive lead close to the supply. The fuse protects the wire and reduces fire risk during shorts or jams. Size it above normal running current, allow for startup surge, and keep it below what the wire, controller, and connectors can safely carry.

Can I control 2 24V actuators from 1 switch?

Yes, if the switch or relay circuit can carry the combined current of both actuators. Standard 2-wire actuators may not stay perfectly synchronized under unequal loads. For aligned motion, use feedback actuators and a compatible controller that handles actuator count, feedback signals, calibration, and current.

Which lead is positive on a 2-wire actuator?

Neither motor lead owns positive permanently. Positive on 1 lead makes the actuator extend or retract depending on the motor wiring. Swapping polarity reverses direction. If the actuator includes feedback wires, keep them separate from the motor leads and follow the controller wiring requirements exactly.

About the Author

Robbie Dickson is the Chief Engineer and Founder of FIRGELLI Automations. With a background in aeronautical and mechanical engineering at Rolls-Royce, BMW, and Ford, he has spent over 2 decades designing precision motion control systems, from linear actuators for robotics to active aerodynamic braking systems for supercars. Read more: Robbie Dickson and Full Bio.