I have wanted to do some writeups on my cab wiring. Here is the first one. It might help other people or at least give some ideas.
First a few cab wiring principles:
- Plan ahead - essential
- Use a color scheme for different voltages (where possible). My scheme is:
- Black - common ground (5V, 12V, and 24V)
- Yellow - 12V (and 24V)
- Red - 5V
- Blue - low-side power output to 12V and 24V toys
- Green - low-side power output to 5V LEDs
- White - common KL25Z ground for buttons
- Use other color coding to help e.g. color of crimp connectors. I have used the following:
- Red - 5V
- Yellow - 12V
- Blue - 24V
- Black or green - ground
- Use the correct gauge wire for the amperage. Use more than one wire for higher currents (easier to handle than one very thick wire)
- 24/26 AWG for signals from buttons etc
- 22/24 AWG for low voltage, low current signals e.g. LED
- 18 AWG for anything needing a higher current e.g. solenoids, chimes, addressable LEDs
- Label, label, label wires (both ends if appropriate) so you can see what is what
- Use screw connectors, crimps, spade terminals etc so you can easily move things around
- Tie things together and keep cables neat - no need to go overboard as you will inevitably need to change things
- Make things flexible and removable
There are multiple ways to provide power for the cab. I decided to standardize on a PC power supply unit (PSU) of 550W, partly because I have several spares. These power supplies have 5V, 12V, 3.3V outputs. Below is a picture of the PC power supply with its maximum ratings. Note that you cannot use everything together as it will exceed the total power rating of the PSU.

Each voltage has different amperage limits and by far the largest rating is for 12V to drive PCIe cards like GPUs. My idea is to use the 12V and then have buck and boost regulators to provide 5V and 24V. The PSU has a fairly common breakout board on top which right now I'm using as a simple way to turn it on and off (the breakout board acts like a PC and most importantly it connects the PWR_ON signal wire to ground to turn on the PSU). The 5V and 12V outputs provide extra fused power connections if I need them.

The PSU has 8 pin and 6 pin PCIe power connector for GPUs etc. I'm going to utilize these power pins to drive power distribution board in the rear of the cab. This rear distribution board includes a 5V buck regulator rated at 150W (30A) and a 24V boost regulator rated at 240W (10A). This will be plenty of power for 24V contractors and 5V real DMD, 5V LEDs, and addressable LEDs. Everything else is 12V.
I have used three busbar connectors for the different voltages (red) and a couple for the common ground (black). The rear power distribution board drives the real DMD, addressable LEDs, rear cooling fans, and 12V for the backbox toys such as the knocker, beacons, and strobe.
The rear power distribution board has one 8-way 16 AWG bundled cable that takes power and ground to the front power distribution board. Four wires are used for ground, one for 5V, two for 12V, and one for 24V. Each wire has a maximum current capacity of 10A and should be fine for everything needed in the front of the cab.

The front power distribution board really consists of two bus bar connectors mounted on the PCB tray. This PCB tray also contains the Pinscape AIO, fuse board, and 3 audio amps (not shown). And as a side-note, the audio amps get their power separately from some laptop power bricks. The front power distribution board powers the Pinscape AIO, button LEDs, rotary encoder and door LEDs, front cooling fans, chimes, shaker motor, gear motor, and the ten 24V contractors.

The indicator on the picture above shows where the color coding can breakdown. The 5V common anode for the four RGB LED flipper boards is actually yellow. This is because the red wire is used for the red LED color. But the crimp is colored red and there is a label on the four bundled wires to indicate its usage. The label is mostly hidden by one of the flipper contractor that is installed above the PCB board.