24 AWG-to-22 AWG VC1/VFD Cable Upgrade Wiring Reference

Use this reference when replacing the original 24 AWG control cable with the approved 22 AWG cable in stationary, carriage, or Linear PickLine panels. The color-to-terminal assignments differ by device and panel, so identify both ends before moving conductors.

Electrical safety: Qualified personnel must lock out the machine and verify that the panel is de-energized before replacing or terminating cable. The machine schematic and terminal labels are authoritative; do not rely on color alone or mix this guide with a different cable standard.

Before disconnecting wiring

1. Identify the exact VFD and VC1 designation, such as DR1 or DR4.
2. Photograph both ends of the existing cable and every terminal label.
3. Tag each conductor before removal.
4. Confirm that the replacement cable is the approved 22 AWG type and has the expected colors.
5. Use the machine schematic to verify every destination. Some VC1s include additional conductors not shown in this standard reference.

Stationary and carriage panel — VFD terminals

• Blue → SG+
• White → SG−
• Yellow → ACM
• Orange → AI1
• Green → FWD
• Red → REV
• Black → DI3
• Brown → DCM; use the documented DCM terminal for that drive.

Stationary and carriage panel — VC1 terminals

• Yellow → 0 V
• Brown → 0 V
• Orange → VOUT+
• White → RS485−
• Blue → RS485+
• Black → O3 (GND)
• Red → O2 (GND)
• Green → O1 (GND)

Linear PickLine panel — VC1 terminals

• Yellow → 0 V
• Brown → 0 V
• Orange → VOUT+
• White → RS485−
• Blue → RS485+
• Black → O3 (GND) on DR4 only; do not use it on DR1, DR2, or DR3.
• Red → O2 (GND)
• Green → O1 (GND)

Termination and verification

1. Terminate one conductor at a time and confirm that no copper strands are exposed.
2. Tug-test each terminal and verify conductor labels at both ends.
3. Check continuity and confirm there is no short between adjacent conductors.
4. Restore power and confirm normal VC1 and VFD communication.
5. Test run, direction, and speed commands at a controlled speed.
6. If any movement operates in the wrong direction or a communication fault appears, stop and compare every terminal with the schematic before changing parameters.