Control Box Wiring Creation

Instructions

Note:

If the control box is going to be wired before being connected to the system then, all of the connectors that require wires from the system should be temporarily skipped. 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.

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
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
If green 22 AWG is not available then, 24 AWG wire is sufficient to ground the system

Black+red or black+white @ PBC, routed from DAQ power booster

Shunt 15V @ PBA:PBB

Shunt +5V @ PBC:PBD

(DO NOT shunt VS5>>)
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
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
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 a pink fork terminal

6" gray 22 AWG wire to a pink fork terminal

6" green 22 AWG wire to a pink fork terminal

   #: Crimp (1) 6" and the black wire from the actuator stack
   #:: If AC2 is present then crimp all three black wires in the same crimp
   #:: Crimp the two wires into a blue fork terminal

Do not crimp the other ends at this time

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 blue fork terminal onto the white wire, together with the white wires from the fan

Crimp a blue fork terminal onto the black wire, together with a 6" black 22 AWG wire

If AC2 is present
Crimp a blue fork terminal onto the white wire, together with the white wires from the fan

Crimp a blue fork terminal onto the black wires, together with a 6" black 22 AWG wire

Connect the terminal with the black wires to -V

Connect the terminal with the white wires to +V

Connect the pink fork terminals from the remaining daisy-chains to the +5V SPS as follows:
green: ⏚

gray: N

violet: L

tighten all terminal screws securely
15V PS (-15V PS does not exist anymore, rename the +15V to 15V and move all needed wires here)
Route the brown wire from the DAQ to +V @ the 15V PS
Trim to length, crimp on a pink fork terminal and connect the terminal

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 inlet
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 black wire from the DAQ and the black wire from +5V 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