153IR Controller wire size

I don't know the answer to your question, but I have studied and posted thoughts about the internal workings of the 153IR in various OGR threads.  Indeed, as you say, the manuals from the current and previous versions of the 153IR have the warnings.  The manual for the current version of the 153IR from 2015 even added an exclamation point!

The internal relay contacts in the 2015 version are rated for 3 Amps whilst the 2002 version is 2 Amps.  To each his own on the level of conservatism with respect to Amp capacity vs. wire gauge.

Separately, I determined that I could fit up to a #50 drill bit (0.070" diameter or about 13-14 gauge) into the 153IR Accessory connector.  But the connector also securely clamps to 30 gauge wire.

With no further information, I'd go with your inclination - if your choice is between 20 and 28, go with 20.

Stan, thanks for your considered response. I see I’m not the only one thinking about that statement in the manual. 

After seeing your response, I wired power INTO the 153IR using 20 gauge stranded wire, and power OUT, from the 153IR to each of the two crossing gates, using 24 gauge stranded wire (both crossing gates powered by a single 153IR by twisting the wires together from the two crossing gates - red to red, black to black, yellow to yellow). Doubling those 24-gauge wires easily fit into the connectors. So far, and I’ve been running a GP7 pulling a few cars for a couple of hours now, the 153IR is working those two crossing gates perfectly. 

By the way, connecting the14098 crossing gates to the 153IR wasn’t exactly intuitive for me, because it didn’t work to use the NC (normally closed) connector to pull the gates back up.  What ended up working was insert red into the 153IR’s ACC PWR, Black into ACC GND, and yellow into NO (normally open), and nothing into NC. Apparently, when the IR beam is triggered, the 153IR connects NO to ACC GND (i.e., connects yellow to black) to pull down the crossing gate arm and power the flashing red lights

I’m surprised more people aren’t confused by the “do not use wire that is larger than 24 gauge!” statement. I haven’t found a single query about that anywhere online. 

Thanks again for your great reply Stan. 

Ken

CaseyKen posted:

 

I’m surprised more people aren’t confused by the “do not use wire that is larger than 24 gauge!” statement. I haven’t found a single query about that anywhere online. 

 

They probably don't read the manual

Brendan

CaseyKen posted:

Stan, thanks for your considered response. I see I’m not the only one thinking about that statement in the manual. 

After seeing your response, I wired power INTO the 153IR using 20 gauge stranded wire, and power OUT, from the 153IR to each of the two crossing gates, using 24 gauge stranded wire (both crossing gates powered by a single 153IR by twisting the wires together from the two crossing gates - red to red, black to black, yellow to yellow). Doubling those 24-gauge wires easily fit into the connectors. So far, and I’ve been running a GP7 pulling a few cars for a couple of hours now, the 153IR is working those two crossing gates perfectly. 

By the way, connecting the14098 crossing gates to the 153IR wasn’t exactly intuitive for me, because it didn’t work to use the NC (normally closed) connector to pull the gates back up.  What ended up working was insert red into the 153IR’s ACC PWR, Black into ACC GND, and yellow into NO (normally open), and nothing into NC. Apparently, when the IR beam is triggered, the 153IR connects NO to ACC GND (i.e., connects yellow to black) to pull down the crossing gate arm and power the flashing red lights

I’m surprised more people aren’t confused by the “do not use wire that is larger than 24 gauge!” statement. I haven’t found a single query about that anywhere online. 

Thanks again for your great reply Stan. 

Ken

Thanks for the post I have some of these to do in the future.

Dave Ripp. posted:

Thanks for the post I have some of these to do in the future.

Dave, I have another 153IR that activates the red light on a signal bridge, then turns back on a green light after the train passes

Lionel did not do themselves a favor by changing the wiring instructions for the 153IR.  I recycled the following side-by-side from an earlier OGR thread.  For the same item number, the instructions differ depending on when you bought it!