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Signal wires: please provide guidance on shielded wires I should use
- behai
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03 Mar 2025 05:32 #323064
by behai
Signal wires: please provide guidance on shielded wires I should use was created by behai
I understand that for signal wires, those from proximity switches and stepper drivers to controller cards, we should use shielded wires.
I am in Victoria, Australia. I am unable to find just "shielded wire", but there are shielded audio, video, data and microphone wires available, for example:
www.altronics.com.au/cable/shielded/?brw...j8i_PHDnOkyFmM9mya9r
I need shielded wires to connect:
1. CL57T-V1 stepper driver's PUL+, PUL-, DIR+, DIR- to Mesa 7I96S.
This driver is rated 24-48VDC, and 3 output currents setting of 2.8A, 5.6A and 7.0A.
Manual: www.omc-stepperonline.com/download/CL57T_V4.0.pdf
2. NPN NO proximity switches signal output to Mesa 7I96S input.
Switch: www.makerstore.com.au/product/elec-lj2a3/
It is rated DC 6-36V, 300mA.
Would you advise on correct shielded wires to use, please?
-- I have only known of "shield wires" about 3 months ago. So please kindly excuse this very basic question. I've only started learning.
Thank you and best regards,
...behai.
I am in Victoria, Australia. I am unable to find just "shielded wire", but there are shielded audio, video, data and microphone wires available, for example:
www.altronics.com.au/cable/shielded/?brw...j8i_PHDnOkyFmM9mya9r
I need shielded wires to connect:
1. CL57T-V1 stepper driver's PUL+, PUL-, DIR+, DIR- to Mesa 7I96S.
This driver is rated 24-48VDC, and 3 output currents setting of 2.8A, 5.6A and 7.0A.
Manual: www.omc-stepperonline.com/download/CL57T_V4.0.pdf
2. NPN NO proximity switches signal output to Mesa 7I96S input.
Switch: www.makerstore.com.au/product/elec-lj2a3/
It is rated DC 6-36V, 300mA.
Would you advise on correct shielded wires to use, please?
-- I have only known of "shield wires" about 3 months ago. So please kindly excuse this very basic question. I've only started learning.
Thank you and best regards,
...behai.
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- unknown
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03 Mar 2025 07:37 #323068
by unknown
Replied by unknown on topic Signal wires: please provide guidance on shielded wires I should use
To tell the truth for connection of step & direction from my 7i76 to the drivers I didn't bother with shielded cables.
When I get around to the limit switches I may use shielded cables, I don't know.
But what I was very particular about was the path of the power cables.
AC power was physically isolated as the installation allowed, at no instance would I allow AC power to cross any signal wire.
At the same time DC power was physically isolated from the AC power and any signalling.
The basic plan was AC/DC run on one side of the cabinet and signals on the other side.
What made my install easier in the above is I used an 18 unit rack cabinet, used upright rails in the middle of the cabinet, thereby giving me twice the area to install gubbins, AC power was assigned to one side of the partition, think relays auxiliary power and such, and the PC Mesa cards and such on the other side all mounted to metal plates.
Another thing I employed, maybe over the top, is using a seperate power supply for powering the relays and contactors that regulate the AC power supplies used elsewhere. All power supplies are controlled via a No Volt Return setup, as I'm lazy I made some PCBs to make the wiring easier, so if I do lose power, thanks to Labor's green madness, the power doesn't come back on and suprise me.
Meanwell & Wiedermuller PSU are used throughout, the servo drive that Powers the AC spindle motor has been installed with the required AC filters and line reactor.
So far I've no issues with interference either from the mill and mill electronics nor with any appliance in the house.
Ok back to your original question, I would have a look on AliExpress for cabling, they seem to have a large range. Some of our local stuff, Jaycar Altronics et all are kind of expensive.
Whatever your do use bootlace ferrules, good quality crimp connectors, do not solder the crimp connectors. A good quality crimp cold welds the wire to the connector, same as wire wrapping. The solder has a tendency to whick up the wire and create a "solid" point where with the right amount of movement it will fracture. Forget what any "YouTube" guru says about soldering they are wrong. Buy good quality crimps and crimp tools, there's a company in Engadine NSW Ive bought all my stuff from and never had an issue.
Ok I come back with some photos and such. Bear in mind this is for a mill install, a plasma setup will have more requirements, Tommy or Rod hopefully will chime in .
I've probably forgotten way too many things as well.
When I get around to the limit switches I may use shielded cables, I don't know.
But what I was very particular about was the path of the power cables.
AC power was physically isolated as the installation allowed, at no instance would I allow AC power to cross any signal wire.
At the same time DC power was physically isolated from the AC power and any signalling.
The basic plan was AC/DC run on one side of the cabinet and signals on the other side.
What made my install easier in the above is I used an 18 unit rack cabinet, used upright rails in the middle of the cabinet, thereby giving me twice the area to install gubbins, AC power was assigned to one side of the partition, think relays auxiliary power and such, and the PC Mesa cards and such on the other side all mounted to metal plates.
Another thing I employed, maybe over the top, is using a seperate power supply for powering the relays and contactors that regulate the AC power supplies used elsewhere. All power supplies are controlled via a No Volt Return setup, as I'm lazy I made some PCBs to make the wiring easier, so if I do lose power, thanks to Labor's green madness, the power doesn't come back on and suprise me.
Meanwell & Wiedermuller PSU are used throughout, the servo drive that Powers the AC spindle motor has been installed with the required AC filters and line reactor.
So far I've no issues with interference either from the mill and mill electronics nor with any appliance in the house.
Ok back to your original question, I would have a look on AliExpress for cabling, they seem to have a large range. Some of our local stuff, Jaycar Altronics et all are kind of expensive.
Whatever your do use bootlace ferrules, good quality crimp connectors, do not solder the crimp connectors. A good quality crimp cold welds the wire to the connector, same as wire wrapping. The solder has a tendency to whick up the wire and create a "solid" point where with the right amount of movement it will fracture. Forget what any "YouTube" guru says about soldering they are wrong. Buy good quality crimps and crimp tools, there's a company in Engadine NSW Ive bought all my stuff from and never had an issue.
Ok I come back with some photos and such. Bear in mind this is for a mill install, a plasma setup will have more requirements, Tommy or Rod hopefully will chime in .
I've probably forgotten way too many things as well.
The following user(s) said Thank You: behai
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- rodw
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03 Mar 2025 09:15 #323074
by rodw
Replied by rodw on topic Signal wires: please provide guidance on shielded wires I should use
I suggest you contact Treotham. They will be in VIC. Call them
treotham.com.au/
For stepper wiring on a couple of machines I have used ÖLFLEX CLASSIC 400 CP 4X0.75 from them
Then had to get it in from overseas but it didn't take long.They will have other options.
This was rated for drag chain use and actually has two layers of plastic sheath as well as the shielding.
To get wires up on the gantry, I use DB9 breakout boards and you can get premade cables from www.lindy.com.au/. These are pretty light weight but sure beats soldering up your own.
The rest of the (unshielded) cabling I mostly use Jaycar hookup wire with bootlace ferrules. You can get a kit with the crimper and ferrules from eBay. The Jaycar wire is a bit light but it works...
treotham.com.au/
For stepper wiring on a couple of machines I have used ÖLFLEX CLASSIC 400 CP 4X0.75 from them
Then had to get it in from overseas but it didn't take long.They will have other options.
This was rated for drag chain use and actually has two layers of plastic sheath as well as the shielding.
To get wires up on the gantry, I use DB9 breakout boards and you can get premade cables from www.lindy.com.au/. These are pretty light weight but sure beats soldering up your own.
The rest of the (unshielded) cabling I mostly use Jaycar hookup wire with bootlace ferrules. You can get a kit with the crimper and ferrules from eBay. The Jaycar wire is a bit light but it works...
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- behai
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04 Mar 2025 04:31 #323121
by behai
Replied by behai on topic Signal wires: please provide guidance on shielded wires I should use
Good afternoon Rob and Rod,
Thank you for very much for your helps. I appreciate the guidance and the info.
I have bought a Preciva HSC8 6-6A bootlace crimpper last month, it comes with 1900 ferrules.
I used it on the single driver I have, I found out that the wires on this driver are of different diameters, that is why I had to use different ferrule sizes:
I am happy with this crimpper, the first one I have ever used
I plan to use to common blocks with the switches. The blocks I have are from Jaycar: www.jaycar.com.au/16-way-100a-brass-busbar/p/SZ2004; they are rated for 100A, but I like how they look.
I have found that these common blocks work well with the ring terminal connectors: once screwed in, they don't come lose easily. The wires with the ring terminal connectors are salvaged from a Japanese Tiger rice cooker, I use salvaged wires during my learning process, but I will use proper wires for the final one. I plan to get a proper crimpper for this, too.
Thank you for the two websites Rod. treotham.com.au/contact is practically next door to my place, There is also a Jaycar store, and www.power-supplies-australia.com.au/ are also in the neighbourhood.
Thank you and best regards,
...behai.
Thank you for very much for your helps. I appreciate the guidance and the info.
I have bought a Preciva HSC8 6-6A bootlace crimpper last month, it comes with 1900 ferrules.
I used it on the single driver I have, I found out that the wires on this driver are of different diameters, that is why I had to use different ferrule sizes:
I am happy with this crimpper, the first one I have ever used

I plan to use to common blocks with the switches. The blocks I have are from Jaycar: www.jaycar.com.au/16-way-100a-brass-busbar/p/SZ2004; they are rated for 100A, but I like how they look.
I have found that these common blocks work well with the ring terminal connectors: once screwed in, they don't come lose easily. The wires with the ring terminal connectors are salvaged from a Japanese Tiger rice cooker, I use salvaged wires during my learning process, but I will use proper wires for the final one. I plan to get a proper crimpper for this, too.
Thank you for the two websites Rod. treotham.com.au/contact is practically next door to my place, There is also a Jaycar store, and www.power-supplies-australia.com.au/ are also in the neighbourhood.
Thank you and best regards,
...behai.
The following user(s) said Thank You: tommylight, rodw
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