RFQ - custom wire harness
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STATUS: request for quotation. Quote 2 full sets, to be
treated as the sample run. Please confirm the revision before
starting production.
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1. WHAT THIS IS
Custom cable assemblies for one machine. 18 cables per set,
listed in section 3. The drawings are in this package as PDF,
PNG, SVG and HTML (generated with WireViz), each with its own
BOM (TSV) and its WireViz YAML source:
  - power, psu-pigtail, board-power : PSU pigtails PJ1-PJ3,
        load cables W1-W3. "power" is the overview, the other
        two are the cables it is made of.
  - steppers, channel-stepper, chute-stepper : channel stepper
        crossover cable S1-S4, chute cable CH. "steppers" is
        the overview.
  - leds, limit-switch : LED feeds L1-L3, pigtails L1p-L3p,
        limit switch LIM. "leds" is the overview.
Quote from the per-cable drawings. The overviews show how the
cables fit together.

2. QUANTITY
2 full sets (every cable in section 3 x2): 36 cables.
Quote 2 sets and price breaks at 10 / 50 sets.

3. CABLE SCHEDULE
Per set. End A is the end that gets the label. Lengths are
finished cable length.

ID           Qty  Length          Wire
PJ1-PJ3      3    100 mm (4 in)   18 AWG, red and black
  A: panel-mount DC jack, female, 5.5 x 2.1 mm
  B: two insulated M3.5 fork terminals
W1           1    920 mm (36 in)  18 AWG, red and black
  A: DC plug, male, 5.5 x 2.1 mm
  B: JST VHR-2 housing, pin 1 = +24 V (red), pin 2 = GND
W2           1    310 mm (12 in)  22 AWG, red and black
  A: DC plug, male
  B: bare, stripped 5 mm and tinned
W3           1    150 mm (6 in)   22 AWG, red and black
  A: DC plug, male
  B: bare, stripped 5 mm and tinned
L1-L3        3    920 mm (36 in)  22 AWG, red and black
  A: 2-position Dupont housing, black in the cavity at the
     moulded arrow, red in the other
  B: inline DC socket, female
L1p-L3p      3    150 mm (6 in)   22 AWG, red and black
  A: DC plug, male
  B: bare, stripped 5 mm and tinned
LIM          1    610 mm (24 in)  22 AWG, black and white
  A: 3-position Dupont housing, position 1 (at the moulded
     arrow) black = ground, position 2 white = signal,
     position 3 empty
  B: two fully insulated #187 female quick-connect
     receptacles
S1-S4        4    1 m (39 in)     24 AWG, blue, green, red,
                                  black, in PVC sleeving
  A: JST PHR-4
  B: JST PHR-6, 4 of 6 positions populated (section 5)
CH           1    300 mm (12 in)  24 AWG
  A: JST PHR-4
  B: bare, stripped 5 mm and tinned
  The far end is spliced onto the chute motor's own flying
  leads, so no connector goes there.

4. WIRE AND CONNECTORS
Wire
- UL1007 stranded tinned copper, 300 V, or RoHS equivalent.
- Gauges: 18 AWG (PJ, W1), 22 AWG (W2, W3, L, L-p, LIM),
  24 AWG (S, CH). 24 AWG is the most the JST PH contact takes.
- Red = +24 V, black = GND on every 2-conductor power cable.
- No UL certification and no IPC-A-620 class required.
  Hobby-grade quality is acceptable; continuity test each
  cable.

Connectors (source to this spec; a part number is the one the
machine was designed against, and any RoHS clone that mates
and crimps the same is fine)
- Board 24 V input: JST VHR-2N housing, JST SVH-21T-P1.1
  contact (W1).
- Stepper board end: JST PHR-4 housing, JST SPH-002T-P0.5S
  contact (S1-S4, CH). Motor end: JST PHR-6 housing, same
  contact (S1-S4).
- DC barrel 5.5 x 2.1 mm, centre-positive, 5 A or better:
  male plugs (W1-W3, L1p-L3p), female inline jacks (L1-L3),
  female panel-mount jacks (PJ1-PJ3). 2.1 mm pin, NOT 2.5 mm.
  The two do not mate.
- Dupont = generic 2.54 mm (0.1 in) female socket housing and
  female crimp contacts (L1-L3, LIM). No keying.
  The moulded arrow on a Dupont housing always marks the
  ground wire: black goes in the cavity next to the arrow,
  and positions count away from the arrow.
  L1-L3: black at the arrow, red in the other cavity.
  LIM: the board end is a 3-position housing with only
  positions 1 and 2 populated: black (ground) in position 1
  at the arrow, white (signal) in position 2, position 3
  empty. Fitted, the arrow end goes over the pin the board
  prints GND.
- LIM switch end: fully insulated female quick-connect
  receptacle, #187 series (4.75 x 0.5 mm / .187 x .020 in
  tab), 22 AWG. Mates the Omron V-155-1C25 limit switch. No
  soldering. Fully insulated because the switch is SPDT and
  one of its three tabs is left unused.
- Spade/fork terminals (PSU end): 18 AWG, M3.5 stud, 8 mm wide
  MAX so they fit the MeanWell LRS-350-24 terminal block. That
  block is 9 screws, numbered per the MeanWell spec sheet:
  1 AC/L, 2 AC/N, 3 FG, 4-6 DC OUTPUT -V, 7-9 DC OUTPUT +V.
  Each pigtail takes one +V/-V pair (7 with 4, 8 with 5,
  9 with 6). Screws 1-3 are not part of this harness.
- Bare ends: strip 5 mm (0.2 in) and tin, no connector.
  W2, W3, L1p-L3p and CH are ordered with one bare end
  because the part they join has its own fixed leads or
  solder pads. They are joined on the machine, not by you.

5. IMPORTANT - CROSSOVER CABLE
Cable S1-S4 (steppers drawing) is NOT straight-through. The
motor end is a 6-position housing with only 4 positions
populated:
  board 1 -> motor 1  (blue)
  board 2 -> motor 4  (green)
  board 3 -> motor 3  (red)
  board 4 -> motor 6  (black)
Motor positions 2 and 5 stay empty. The positions are the ones
on the wire diagram in the StepperOnline 17HE15-1504S
datasheet: coil A is motor positions 1 and 4, coil B is 3 and
6. See the channel-stepper drawing.
All other cables are straight-through, wire for wire. The
Dupont leads (L1-L3, LIM) are wired by colour as in section 4.

6. TOLERANCES, LABELS, PACKAGING
- Length tolerance +/-10 mm (+/-0.4 in); +/-25 mm (+/-1 in) is
  fine on anything 920 mm (36 in) or longer.
- Label each cable near end A with its ID (W1, S1, CH, ...).
  Label S1-S4 at BOTH ends: four identical cables land within
  inches of each other at both the board and the motors, and
  they are unrecoverable once unplugged. Printed wrap-around
  laser labels or printed heat-shrink are both fine.
- Bag per cable type, ID on the bag. No other packaging
  requirement.

7. QUESTIONS WE EXPECT / PRE-ANSWERED
- Samples first? Yes: treat the 2 sets as the sample run.
- Brand of wire/connector? Any RoHS clone is fine.
- Drawings in DWG/PDF? PDF attached; no DWG exists.
- Test requirement? 100% continuity, every conductor end to
  end, and on S1-S4 against the position map in section 5.
  No hipot needed.
- Cables not listed (ribbons, USB cables, mains cord)? Not
  part of this order; they are bought ready made.
