G-Penny 800W Spindle Upgrade on S3XL

The 16/4 cable assembly I purchased already has an end soldered on it. Even if I took it off; the cable itself not fit into the new smaller connector body. Plus the solder cups in the new connector won’t accept 16 ga wire.

So I’m looking around for 18/4 shielded cable with a drain wire. I’m going to verify 18 ga fits into the solder cups before ordering the cable.

My leading candidate so far is
http://www.onestopbuy.com/wire-cable/A21804-41567.asp

Just curious and 16g would be big. And unusable if connector is smaller than wire. 18g is fine, if it fits…

Ouch, 75 ft minimum? Have you checked with any local suppliers? I’ve even seen some shielded at orange or blue big box…

Going to take a look at that stuff at HomeDepot tomorrow. I want something with 600V insulation rating if I can get it.

Assuming you can’t get your money back for that cable and that it has a braded rather than foil shield (like your other “leading candidate”), why not cut the connector off, strip the jacket off the cable, and if the 4 individual insulated wires fit the spindle connector’s backshell, cut off however many wire strands are necessary to fit the connectors solder cups? If the individual wires don’t fit the backshell, you can splice smaller gauge pigtails to them that fit everything.

I have to chime in on this idea and highly suggest you not do this kind of patching. Anywhere.

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The supplier will take the cable back so I won’t take it apart

Found a great alternative for the cable by the foot. The last one was 18 AWG (7 strands of 26 AWG) and this new one is 18 AWG (16 strands of 30 gauge). Definitely more flexible and they have a 20 ft minimum. I may order $50 worth (about ~50ft) to hit the free shipping and do the stepper cables as well. The cable is rated for 600v which is what I wanted and the diameter is perfect for the connector on the 800W spindle.

https://www.automationdirect.com/adc/shopping/catalog/cables/bulk_multi-conductor_cable/flexible_control_cable/18_awg_shielded/mctc-18-4s-1

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“not suitable for continuous flexing applications” and "3.96 Minimum Installed Bend Radius (inches)"

“these cables are ideal for both stationary and flexible applications with limited mechanical stress and free movement without any tensile stress, loads or forced movements”

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That is close to the ideal stranding for portable cordage and with the 600V rating the sheath is plenty thick. (I don’t know why you spec’d out the 600V. That probably is overkill and will make the cable a bit more stiff, but not that you will notice in this application.)

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I ordered 51ft of it today to get free shipping and it came to just under $53. I’ll have enough to do the stepper motors or sell off lengths to other doing the upgrade too. I’ll report back once I get it

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I have the Beaver Proximity Switches installed and absolutely love them. About the only thing I don’t like is the header wrapped in electrical tape used to connect the power to the switches. (see highlighted area in photo)

I broke the black +5v wire disconnecting it so I decided to clean it up using some wires I bought on Amazon and a little soldering

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The new 18/4 cable came in today. One word to describe it is FANTASTIC! It’s very flexible. More to come as I start to build using it.

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Stepper Motor Cable upgrade to shielded 18awg
Now that the cable is here I measured the actual diameter of the cable to determine the connectors I need to rewire the stepper motors.

The cable insulation is 7.9 to 8mm in diameter so I decided to use GX16 butt joint aviation connectors at the stepper motor. I’ll get about the right amount of compression on the cable jacket to give a secure connection (specified at 6.5mm opening when tightened down).
I originally intended to use GX12 but they would have been too tight. So I ordered the larger GX16-5 (5 pin) butt joint connectors so I can run the 4 wires for the stepper and be able to run the ground wire through the extra pin in case I want to use it in the future.

The other end of the wires uses a Molex connector. After a bunch of research I found the part number of the existing Molex housings used on the stepper cables is 09508043 which should be the polarized version of the 4 pin connector. The pins for that connector that accommodate 18awg wire are Molex part number 08-52-0072. I’ll confirm that they’re the right stuff as they arrive but the aviation connectors have a long lead time (over 30 days). In the interim I’ll reassemble using the stock stepper motor cables to avoid the downtime. The pic below shows the version with more pins but I ordered the 4 pin version.

21pSpEDEj3L

Today I hope to power up the VFD and start setting parameters. Thank you @Julien for the excellent list you compiled in another thread.

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Drag chains anchored in place with M4 screws and I made a transition piece out of and old piece of steel I had.

Started routing the hoses and cables through the drag chains and dry fit the spindle. Looks really good with the blue lol and it fit really well too. This afternoon I’m going to build the power cable from the VFD to spindle. Using old stepper cables for now.

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Well I got the 19W pump mounted on the rear frame bracket. It was convenient place to put it and will good routing of the hoses. Using “pink” Autozone RV Antifreeze good to -50F.

Best of all: NO LEAKS when I tested it.

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Here is a picture of the spindle and you can see the flow gauge.

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I got it running today with the Shapeoko controlling the spindle speed.

I basically wired it like @Luke suggested except I put a NC Emergency stop switch to replace the FOR to DCM jumper. Push the button and the spindle stops quickly. I think this is a nice improvement

Remainder is the standard
PWM - VI
GND - ACM

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First test cut of the new spindle. I love how quiet it is. I’ll take more pictures detailing the installation after I get the work area cleaned up. All I can say is WOW and I’d wish I’d done it sooner. It’s Vcarving a couple of Beer Taps in the video

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