Wiring check wanted

[zappafan1]

Hello, all: I'd like to get this wiring checked before I power-up the unit. The drawing is one I massaged, courtesy of Keling. If I'm correct, connections 5 and 6 on the G540 is a controlled ground. Anyway, thanks for your time. All comments are welcome. By the way, one DB9 connection wire to the limit switches needs to be changed, I know. I'll also be adding a circuit breaker on the A/C Input.

[morestuff]

Ignoring limit switches as requested, then the
relays are wired to the G540 correctly.

The motor loads controlled by the relays are not
wired correctly. You show each motor powered
between the relay switched Hot lead of the mains
and the safety Ground for the mains. While you
may indeed have a connection to safety Ground
from each motor, the power to the motor must
be between the relay switched Hot and the
Neutral of the mains.


Also, as you said, a power switch and a fuse or
circuit breaker is needed in the Hot side of the
connection to the mains.

Regards,
Steve Stallings
www.PMDX.com

[LeeWay]

My relays get all the low voltage from the BOB. Not the PS. I think mine go from 3VDC to 24VDC. Anything in that range activates them.

[zappafan1]

Ignoring limit switches as requested, then the
relays are wired to the G540 correctly.

The motor loads controlled by the relays are not
wired correctly. You show each motor powered
between the relay switched Hot lead of the mains
and the safety Ground for the mains. While you
may indeed have a connection to safety Ground
from each motor, the power to the motor must
be between the relay switched Hot and the
Neutral of the mains.


Also, as you said, a power switch and a fuse or
circuit breaker is needed in the Hot side of the
connection to the mains.

Regards,
Steve Stallings
PMDX.COM - Products for CNC and motion control applications

Thanks, Steve: It took a couple of days before I heard from GeckoDrive, and they emailed me right after your response.

What I'm doing (as much as possible) is to keep any wiring to and from the G540 using the power supply Hot and Neutral; and, anything using 115 A/C is on the "output" side of the relays. The spindle motor has a direct path to Earth ground, as will the Coolant Pump. I try to keep the "Earth" ground as separate as possible, from what I call the "System Neutral."

Marcus from GeckoDrive says it all looks good, so how can I not go with that advice? There IS a Power On Switch in the circuit, though not in that drawing. The reason I said to disregard the DB9 connector, is I have to change the wire trace from the Centering Probe from Pin 2 to Pin 5.

I choose to use 115VAC right now, until I upgrade the machine with a 2.2kw water cooled spindle, and double the size of the steppers; then I'll switch to 230VAC. Thanks, again. I'd call myself a "moderate" newbie, so any thoughts are always welcome.

[LeeWay]

Okay. Maybe I don't understand the layout. I think the relay would stay on all the time with that setup. You need the output from Mach to provide from 3 to 24V to engage the relay.
The power supply is providing that voltage constantly. No relay.

On a side note, that might actually fry something.

[Khalid]

When done, kindly update the sketch and post here. Many will benefit from the sketch and some one can point out if still some minor errors persist.

[zappafan1]

Okay. Maybe I don't understand the layout. I think the relay would stay on all the time with that setup. You need the output from Mach to provide from 3 to 24V to engage the relay.
The power supply is providing that voltage constantly. No relay.

On a side note, that might actually fry something.

Voltage is constantly going to one side of the relays, but pins 5 and 6 are ground paths controlled by Mach3. So, without a ground, the relays are open. When you use Mach3 to turn on that circuit (water pump and/or spindle), then one (or both) are routed to ground, completing the circuit. Yea? No? Since pins 5 and 6 are Outputs, I wouldn't think it wise to supply input voltage there.

I emailed Marcus again, and I will post my email and his reply.... should be tomorrow. Thanks! John

[zappafan1]

Okay. Maybe I don't understand the layout. I think the relay would stay on all the time with that setup. You need the output from Mach to provide from 3 to 24V to engage the relay.
The power supply is providing that voltage constantly. No relay.

On a side note, that might actually fry something.

Here's two somewhat different wiring setups: One from an internet CNC site, which has it's own power supply to the relays, and the other one from Homan Designs, which is the diagram I altered to depict my setup. Your Thought?

[LeeWay]

Okay. I have a 540 that I have not wired up yet for a plasma cutter.
I have other machines with 201's and V203's. Those use a BOB that carries 5VDC. That is from a PS, so in effect, I think it would be about the same as what you are doing on the 540.
I just didn't like the fact that you were switching the ground, but it should still work.
BTW, no expert here. Just been forced to pick some stuff up through the school of hard knocks and brilliant spark storms.

[port_huon]

The G540 documents say that OUTPUT1 (pin 5) and OUTPUT2 (pin 6) switch ground i,e, the positive voltage is connected to the other side of the load (relay)

As far as the AC motors go, they should be connected between live and neutral not live and earth.

[zappafan1]

The G540 documents say that OUTPUT1 (pin 5) and OUTPUT2 (pin 6) switch ground i,e, the positive voltage is connected to the other side of the load (relay)

As far as the AC motors go, they should be connected between live and neutral not live and earth.

That is absolutely correct on both counts, although it's not as large an issue on low voltage, yes, use neutral instead of earth ground. This is one of the first times I've ever had a switch on a neutral. Thank you. John

[zappafan1]

Okay. Maybe I don't understand the layout. I think the relay would stay on all the time with that setup. You need the output from Mach to provide from 3 to 24V to engage the relay.
The power supply is providing that voltage constantly. No relay.

On a side note, that might actually fry something.

OK.... the "outputs", pins 5 and 6 of 12 on the G540, are actually a type of switch, which can be controlled by Mach3, and they provide a path to ground. So, since my pump and spindle are both 115vac, I'm using line input power to supply those units. The 24 VDC from the power supply powers the relays, pins 5 and 6 switch the relay on or off through Mach3.

And, yes, the spindle motor..... a two wire plug..... will be connected to the 115VAC neutral and NOT Earth ground; the coolant pump, being a three- prong cord, will be connected as usual. I will update my drawings and post later today. John