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Thread: G540 E-Stop

  1. #49
    Member kolias's Avatar
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    Hello John

    Very nice schematic, thank you, but I don't understand the numbers for the relays. I will study it more to see if I can make any sense.

    I attach here the PDF file of my old relays, I can't see any ID for the terminals but perhaps you can. Also attached are more pics of these relays

    Attached Thumbnails Attached Thumbnails G540 E-Stop-relays1a-jpg   G540 E-Stop-relays3-jpg   G540 E-Stop-relays4-jpg   G540 E-Stop-relays-data-sheet-ku-6269-pdf  

    Nicolas


  2. #50
    Member kolias's Avatar
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    Don't know how important it is but I made a mistake on the terminals ID of the three 24VDC relays I got.

    The attached pic shows how the terminals are marked on the relays, COM and NO. The terminals A & B have no markings but I put the letters on my own to help me identify which wire will be connected on them

    Attached Thumbnails Attached Thumbnails G540 E-Stop-relays-wiringb-jpg  
    Nicolas


  3. #51
    Member john-100's Avatar
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    Hi Nicolas ,

    for some reason I had the old style octal relay in mind
    now I've seen the relay , I have edited the diagram in post 48 to correct the terminal numbering and include the Potter & Brumfield T9AP1D52-24 relay

    as your only using the common and normally open relay connections
    it doesn't matter which terminal is live and which is the switched live out

    when using a 2 pole relay as a single pole switch you can connect two switches in parallel ( linking commons 7 to 9 and normally open contacts 4 to 6)

    I've been thinking about the E-stop switches you have with both N/O and N/C contacts
    you could use a NPN transistor and a resistor to enable you to use the N/O contact to dissable the G540

    If you buy the E-stop switch with two N/C contacts you don't need the mains powered E-stop relay in the first diagram (G540 wiring schematic v4)
    as one N/C contact can be used to connect the G540 terminals 10 & 12

    John

    Attached Thumbnails Attached Thumbnails G540 E-Stop-g540-wiring-schematic-v4-jpg   G540 E-Stop-g540-wiring-schematic-v5-jpg  
    Last edited by john-100; 06-04-2012 at 08:55 AM.


  4. #52
    Member kolias's Avatar
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    Beautiful job John, took me some time but I now understand both schematics, thank you

    The eBay guy from UK did not reply yet about the Estop with the two NC contacts and since I prefer not to buy another Estop lets forget for now the schematic v5.jpg (2 of 2)

    On schematic v4.jpg (1 of 2), the Estop relay with the 120V AC coil I guess I will have to buy this relay. Are any other specs I need to buy this relay or should be identical to KU-6269 but with 120V AC coil?

    Just to confirm: for the relays 1 and 2 I will use the two KU-6269 relays I now have

    And some minor questions:

    The system on/off switch is this considered a Reset switch?

    The 120V Neon light indicator I was planning to use a 22mm round red light which looks like a push button and rated for 120VAC. I guess it will be ok

    Nicolas


  5. #53
    Member john-100's Avatar
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    Hi Nicolas ,

    yes ,connect the two 24V KU-6269 relays to the G540

    the second diagram had a 2N2222 NPN transistor plus 10K ohm resistor to use the E-switches you have , as in your picture in post 47

    the transistor and resistor enables the G540 until the N/O E-stop switch is operated and connects the transistors Base and Emitter terminals together
    its a way of using the E-stop switches you have without needing the 120V AC relay


    if you decide not to build the transistor circuit and use a relay with the 120V ac coil and a single pole N/C stop switch instead

    choose one with a large gap or barrier between the switch terminals and the two coil terminals

    one like this one it has the added advantage it can't be mixed up with one of the 24V relays :---
    9AS152-120 Magnecraft / Schneider Electric General Purpose / Industrial Relays


    John

    Last edited by john-100; 06-04-2012 at 11:54 AM.


  6. #54
    Member kolias's Avatar
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    Just came back from the store and I got the 2N2222 plus the 10K resistor (see attached pic), not sure yet if I will use them. The transistor has 3 contacts; how do I connect it and I will assume it can take the heat from a soldering gun?

    Also that store has many relays in various bins for about $5.00 each and the base for another $4.00 (that is where I bought my KU-6269). Got some info from two relays I choose (did not buy them yet).
    One relay is #157-01T1A4, 120VAC, 5A, 1/8HP 120VAC / 5A, 1/4HP 240VAC
    The other is MK2P, 10A, 250VAC / 30VDC
    Is any of the above ok?

    Don’t mind to get the one you choose from Mouser but it cost $19.18 + shipping.

    Technically which is a better / safer circuit, the one with the 120VAC relay or the one with the 2N2222?

    Thank you John and sorry for all these problems; in Canada is not that easy to get this kind of parts, eBay or US is the best source

    Attached Thumbnails Attached Thumbnails G540 E-Stop-2n2222-jpg  
    Nicolas


  7. #55
    Community Moderator Al_The_Man's Avatar
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    Quote Originally Posted by kolias View Post

    Don’t mind to get the one you choose from Mouser but it cost $19.18 + shipping.

    Technically which is a better / safer circuit, the one with the 120VAC relay or the one with the 2N2222?
    ; in Canada is not that easy to get this kind of parts, eBay or US is the best source
    For US source I always use Digikey if possible, overnight air for $8.00, no duty or brokerage.
    If you order over $200. it is free shipping.
    Also they have one of the largest inventories I have come across.
    Al.

    CNC, Mechatronics Integration and Custom Machine Design

    “Logic will get you from A to B. Imagination will take you everywhere.”
    Albert E.


  8. #56
    Member john-100's Avatar
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    Hi Nicolas ,

    The one potential flaw with the normally open switch and transistor circuit
    is you do not know if the switch or its wiring was open circuit until you push the E-stop switch !

    the normally closed part of the E-stop switch will still disconnect the mains supply as in the Homann design circuit
    so the machine would stop but the G540 E-stop circuit would not be tripped
    on the plus side it uses a switch you all ready have


    the circuit using the mains powered relay to connect the G540's
    enable input and ground together
    will fail safe as any break in the circuit will trip the G540's E-stop

    if you use the transistor circuit ,
    will you build it on a piece of perf board (Vero board) or epoxy it into a plastic case like the SS441 hall effect switch in the Roman Lini DIY limit switch


    http://www.cnczone.com/forums/open_s...made_easy.html

    when using a soldering gun to solder to the transistor
    you can use a small pair of pliers as a heat-sink on the transistors wires , just where they emerge from the plastic
    ( an elastic band around the handles will hold them closed)

    John

    Last edited by john-100; 06-04-2012 at 06:07 PM.


  9. #57
    Member kolias's Avatar
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    Hi John

    I think I will choose the schematic with the relay. I can get the one you suggested from Mouser or this one from Digikey which I think is similar. Please let me know and I will order one or the other

    http://www.digikey.com/product-searc...yWords=z814-nd

    I also have found on ebay the attached Estop with two NC and two NO contacts ($8.00 with free shipping from Hong Kong)

    In addition I found the attached on/off switch to use it as the system on/off switch. Same cost as the Estop.

    Please let me know which relay to get and if the Estop and on/off switch are good for me.

    Al thank you for the info

    Attached Thumbnails Attached Thumbnails G540 E-Stop-estop-jpg   G540 E-Stop-systemon-jpg  
    Nicolas


  10. #58
    Community Moderator Al_The_Man's Avatar
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    Quote Originally Posted by kolias View Post

    In addition I found the attached on/off switch to use it as the system on/off switch. Same cost as the Estop.

    Please let me know which relay to get and if the Estop and on/off switch are good for me.

    Al thank you for the info
    Also look at Princess Auto if you have one near you, they had some P.B.s and E-stop P.B.s, cheap a while ago.
    You may even find a relay there?
    Al.

    CNC, Mechatronics Integration and Custom Machine Design

    “Logic will get you from A to B. Imagination will take you everywhere.”
    Albert E.


  11. #59
    Member kolias's Avatar
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    I know about PA, they are about 1.5hrs driving away from me and never thought to look for Estop / PB. PB only 12VDC and Estop they have one with either NO or NC contacts, same price as Hong Kong and when I add the shipping / taxes becomes much more expensive.

    Good to know

    Nicolas


  12. #60
    Community Moderator Al_The_Man's Avatar
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    I tend to prefer the Telemecanique line, ebay 261034779532 or 120924892277
    you can get them in mushroom head P.B. or the same with Push lock on - twist off.
    You can stack N.O./N.C. contacts as needed.
    Al.

    CNC, Mechatronics Integration and Custom Machine Design

    “Logic will get you from A to B. Imagination will take you everywhere.”
    Albert E.


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