RFQ - Sorter V2 wire harness
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STATUS: DRAFT - NOT VALIDATED. Values marked GUESS in the
drawings are engineering guesses, not measurements. Do not
start production without a confirmed revision.
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1. WHAT THIS IS
Custom cable assemblies for one machine (a parts sorter).
3 drawing sets are attached (PDF/PNG/SVG/HTML, generated with
WireViz), each with its own BOM (TSV):
  - power     : PSU pigtails PJ1-PJ3, load cables W1-W3
  - steppers  : channel stepper crossover cable S (x4), chute cable CH
  - leds      : LED feeds L1-L3, pigtails L1P-L3P, limit switch LIM

2. QUANTITY
2 full sets (i.e. every cable in the drawings x2).
Per set: 3x PJ, 1x W1, 1x W2, 1x W3, 3x LED feed,
3x LED pigtail, 1x LIM, 4x S, 1x CH  = 18 cables.
Quote 2 sets and price breaks at 10 / 50 sets.

3. WIRE SPEC
- UL1007 stranded tinned copper, 300V, or RoHS equivalent.
- Gauges per drawing: 18 AWG (PJ, W1), 22 AWG (W2, W3, L, LIM),
  24 AWG (S, CH).
- Colors per drawing (red=+24V, black=GND on power pairs;
  steppers BU/GN/RD/BK as drawn).
- Cable S is a 4-wire bundle in PVC sleeving.
- No UL certification / no IPC-A-620 class required. Hobby-grade
  quality is acceptable; continuity test each cable.

4. CONNECTORS
- JST VHR-2 + SVH-21T-P1.1 (board 24V in), JST PHR-4 and
  PHR-6 + SPH-002T-P0.5S (steppers). Clone equivalents
  acceptable.
- DC barrel 5.5 x 2.1 mm, center-positive: male moulded plugs,
  female inline jacks, female panel-mount jacks (>=5A).
  2.1 mm pin, NOT 2.5 mm. The two do not mate.
- Dupont = generic 2.54 mm female socket housing + crimps.
  LIM board end is a 3-position housing with only positions 1
  and 2 populated, so it cannot be fitted backwards.
- 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.
- Ends marked "bare tinned": strip 5 mm and tin, no connector.

5. IMPORTANT - CROSSOVER CABLE
Cable S (steppers drawing) is NOT straight-through. The motor
end is a 6-position housing with only 4 positions populated:
board 1 -> motor 1, board 2 -> motor 4, board 3 -> motor 3,
board 4 -> motor 6. Motor positions 2 and 5 stay empty.
See the drawing.
All other cables are straight-through pin 1 -> pin 1.

6. TOLERANCES, LABELS, PACKAGING
- Length tolerance +/-10 mm (+/-25 mm acceptable on >=36 in).
- Label each cable near end A with its ID (W1, S, 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. 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; no hipot needed.
