Splicing Small-Gauge, Low Voltage, Stranded Wire

Preface

This guide was written specifically for providing instructions on adding an alternate power source for nova red dot module using a step-down buck converter to get 5v DC from an internal 24v DC rail in the machine.

But… best practices, developed for the typical end-user, are reflected here and applicable for most of the low voltage wiring in the machine. Just be sure to choose the correct size connector based on number of wires and wire size for each.

You will likely be dealing with 20 AWG ~ 24 AWG wire in the red dot power cable, depending on where you splice... so it may be smaller than most of the other low voltage wires in the laser. Much of the wiring on the laser power systems is typically 14~18 AWG for the North American Thunder Laser machines.

Safety Considerations

Please see this important information and if in doubt, contact tech support or a qualified professional.

Important Life Safety Notice

Injury, death, loss of property, fire, electric shock, malfunction, reduced performance & machine life, and critical failures can result from not reading, understanding, and following the Operation Manual: 

Nova Series Users Manual

Voltages Present in Thunder Equipment

There are many hazards to be aware of when working with our machines. You will be dealing with 110V AC 60Hz power that can deliver up to 20A (it only takes 0.5A to kill you) across the entire Thunder Laser USA lineup. 

The Nova series machines with water-cooled DC excited glass tubes utilize a high voltage DC power supply that is capable of outputting 30,000V DC at 30mA and more. The HVLPS Output (big red wire) should NOT be metered. That wire is big, red, and scary for a reason.

The Nova and Odin series have 2 DC power supplies: a 24VDC for the electronics, lighting and signaling, etc..., and a 36V DC LVPSU dedicated to the X and Y axis motors.

The Thunder Laser machines outfitted with air-cooled RF excited metal tubes will not have a 30KVDC HVLPSU. The RF tubes are powered by a 48V DC LVPSU.

Other Dangers and Hazards

Besides the risk of electrocution, you must be mindful of the motion control components, peripherals, etc... as well as the CO2 laser beam itself. The moving parts of these systems can injure, pinch, trap, and even kill you so pay attention and, if you are not confident (or competent) to perform any of these tasks, you should consult someone who is.

Basic Things To Have On Hand

Connectors

Red crimps should be the correct size for connecting a few 20~24AWG stranded wires (connecting the red dot pointer power wires to the wires on the 5v out on the converter). Blue can probably work too, in a pinch. Yellow is too big for smaller sized wires.

If you have an assortment of these, you should be fine.

Wire Strippers/Crimpers

Also, some wire strippers with slots for different sizes is needed, as well as the crimping dies that have the notch. They can be separate tools or combos. 

IMPORTANT NOTE ON CRIMPING

The orientation of the dimple that is created by the crimping die needs to be opposite the seam in the body of connectors of this type:

It's sometimes a good idea to lightly bend female spade connector so that the space between the contact points of the spade (green lines) is reduced, so it will be snug on the lug. And note the seam in the barrel of the connector (red arrow)

Digital Multimeter

This is optional but recommended. You may already have one at the ready If you were directed here from a support ticket.

More on meters here:

Recommended Testing & Maintenance Equipment

How To Use A Multimeter

*If you were directed here for the basic wiring splicing information, you can stop here if you like, unless instructed otherwise. Most of the remaining information is specific to installing a buck converter to create another 5v DC power source for the red dot module.

Red Dot Alternate Power Source Info

This guide was written specifically for providing instructions on adding an alternate power source for nova red dot module using a step-down buck converter to get 5v DC from an internal 24v DC rail in the machine.

This is sometimes done if the 5v rail blows on the TL timer board but the rest of the board functions properly. Adding a power source for the red dot is much more cost effective than replacing the entire tl timer board just to get red dot power again.

You will likely be dealing with 20 AWG ~ 24 AWG wire in the red dot power cable, depending on where you splice... so it may be smaller than most of the other low voltage wires in the laser. Much of the wiring on the laser power systems is typically 14~18 AWG for the North American Thunder Laser machines.

Converter

This is the exact part these directions are built around:

https://www.amazon.com/Converter-Step-Power-Supply-Module/dp/B0CBNLVTVZ/

Connection to 24v DC IN

·        Connect the RED wire of the red dot cable to the RED wire of the adapter

·        Connect the BLACK wire of the red dot cable to the BLACK wire of the adapter

         

Connection to Red Dot Power Cable

·        Connect the BROWN wire of the red dot cable to the YELLOW wire of the adapter

·        Connect the BLUE wire of the red dot cable to the BLACK wire of the adapter