Control Box Wiring Creation
Instructions
Note:
Prior to this, R and B valve cables should be installed and routed to an actuator controller, and the LN supply solenoid cable should be installed.
- Ground the vacuum line plumbing:
- Green 22 AWG @ fitting hanger, route to 15V PS
- Remove the plastic shroud from a pink male quick-disconnect terminal
- Crimp the wire into the terminal
- Secure the flat male blade of the terminal between the hanger screw and the fitting
- Route the cable through the frame to the 15V PS in the control box
- Green 22 AWG @ fitting hanger, route to 15V PS
- Modify the AC power cable from the USB PS:
- Cut the AC power cable from the USB PS to a length
- Sufficient to route it to the L and N terminals of the 15V PS
- Strip the sheath to expose a length of wires convenient for routing
- Cut the AC power cable from the USB PS to a length
- Route and connect the panel-mounted USB 3.0 SS cable to the USB hub
- Route and connect the USB PS output cable to the USB hub
- Route and connect a 1.5ft USB 2.0 A-B cable from the USB hub to the DAQ
- Locate the DAQ power booster and route its cable to the DAQ PBC input power pins
- The DAQ power booster is one of: USB hub, +5V SPS, or other +5V PS
- DAQ U6-IFC: connect
- 30" brown 22 AWG @ 15V, route to 15V PS
- 30" black 22 AWG @ GND (by VSS option), route to 15V PS
- 30" green 22 AWG @ Frame, route to 15V PS
- Black+red or black+white @ PBC, routed from DAQ power booster
- Shunt 15V @ PBA:PBB
- Shunt +5V @ PBC:PBD
- (DO NOT shunt VS5>>)
- SB1 stack: connect
- 30" black+white 24 AWG ribbon @ 5V on DC, route to DAQ PBD by barometer
- 36" green+blue+violet 24 AWG ribbon @ UCOM on DC, route to USB hub
- 24" gray+violet 24 AWG ribbon @ 120VAC stack power inlet (beneath stack), route to 15V PS
- Leave sufficient service loop to plug into stack power with stack power removed from stack
- AC1 stack: connect
- 30" black+white 24 AWG ribbon @ 5V on DC, route to +5V SPS
- 30" green+blue+violet 24 AWG ribbon @ UCOM on DC, route to USB hub
- 30" green+blue+violet 24 AWG ribbon @ DCOM on DC, route to USB hub
- AC2 stack: connect
- 36" black+white 24 AWG ribbon @ 5V on DC, route to +5V SPS
- 36" green+blue+violet 24 AWG ribbon @ UCOM on DC, route to USB hub
- 36" green+blue+violet 24 AWG ribbon @ DCOM on DC, route to USB hub
- HC stack: connect
- 22" black+white 24 AWG ribbon @ 5V stack power inlet (beneath stack), route to DAQ PBD by barometer
- Leave sufficent service loop to plug into stack power with stack power removed from stack
- 10" green+blue+violet 24 AWG ribbon @ UCOM on each HC
- 22" gray+violet 22 AWG @ 120VAC stack power inlet (beneath stack), route to 15VDC PS
- Leave sufficent service loop to plug into stack power with stack power removed from stack
- 22" black+white 24 AWG ribbon @ 5V stack power inlet (beneath stack), route to DAQ PBD by barometer
- Power Inlet corner: connect
- 3" black 16 AWG jumper from L @ IEC inlet to fuse
- 3.25" black 16 AWG jumper from fuse to NO @ switch
- 14" black 16 AWG from COM @ switch to 15V PS
- 14" white 16 AWG from N @ IEC inlet to 15V PS
- 14" green 22 AWG from G @ IED inlet to 15V PS
- Route the cables and wires to their destinations, bundle using zip tie
- +5V SPS
- 6" violet 22 AWG wire to fork terminal as follows:
- Crimp into pink fork terminals
- 6" gray 22 AWG wire to fork terminals
- 6" green 22 AWG wire to fork terminals
- Daisy-chain (1) 6" and (1) 6-3/8" black 22 AWG wire to fork terminals as follows:
- Crimp the two wires into a blue fork terminal
- Do not crimp the other ends at this time
- Crimp the two wires into a blue fork terminal
- Route the black+white ribbons from the AC stacks to +V @ the +5V SPS and cut to length
- Split the wires and trim the black wires 3/8" shorter than the white ones
- If AC2 is absent
- Crimp a pink fork terminal onto the white wire
- Crimp a blue fork terminal onto the black wire, together with the 6" black wire from the black daisy-chain
- If AC2 is present
- Crimp a blue fork terminal onto the white wires
- Crimp a blue fork terminal onto the black wires, together with the 6" black wire from the black daisy-chain
- Connect the terminal with the white wire(s) to +V
- Connect the terminal with the black wires to -V
- Connect the pink fork terminals from the remaining daisy-chains to the +5V SPS as follows:
- green: <earth ground symbol>
- gray: N
- violet: L
- tighten all terminal screws securely
- +15V PS
- Route the brown wire from the DAQ to +V @ the 15V PS
- Trim to lenght, crimp on a pink fork terminal and connect the terminal
- Connect the blue fork terminals from the daisy-chains assembled above as follows:
- Black: -V
- Green: <earth ground symbol>
- gray: N
- Violet: L
- Tighten all terminal screws securely
- 15V PS (does not exist anymore, rename the +15V to 15V and move all needed wires here)
- Route the black wire from the power switch
- Route the violet wire from the HC 120VAC stack power CCA to L @ the 15V PS
- Trim the wires to length, crimp them together into a blue fork terminal
- Insert the terminal backwards, leaving the screw loose
- Route the black wire from the USB PS AC power cable
- Route the violet wire from the SB 120VAC ribbon
- Route the violet wire from the +5V PS to L @ the 15V PS
- Trim the wires to length, crimp them together into a blue fork terminal
- Connect the terminal, stacked in from of the backwards one
- Route the white wire from the ICE power intlet
- Route the gray wire from the HC 120VAC stack power CCA to N @ the 15V PS
- Trim the wires to length, crimp them together into a blue fork terminal
- Insert the terminal backwards, leaving the screw loose
- Route the white wire from the USB PS AC power cable
- Route the gray wire from the SB 120VAC ribbon
- Route the gray wire from the +5V PS to N @ the 15V PS
- Trim the wires to length, crimp them together into a blue fork terminal
- Connect the terminal, stacked in front of the backwards one
- Crimp the four green wires routed to the 15V PS together into a blue fork terminal
- Connect the terminal to [the earth ground symbol] @ the 15V PS
- The wires come from: the IEC inlet, the vacuum system frame, Frame @ the DAQ, and the daisy-chain to the other power supplies.
- Crimp the two black wires routed to the 15V PS together into a blue fork terminal
- Connect the terminal to V+ @ the 15V PS
- The wires come from GND @ DAQ (by VSS option) and the wire +5V PS
- Route the black wire from the power switch