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4_AX_SYS_KIT

4_AX_SYS_KIT

DO NOT ORDER. NEW SYSTEM KIT AVAILABLE.

4 Axis System Kit
This item ships via USPS Priority mail using the address you provide when making the Paypal payment. It is imperative that the correct shipping address is filled out when completing the transaction through Paypal.

The 'System Kit' Includes:
(4) TB6600 Single Axis Stepper Motor Drives
(4) 425 oz.in. Bipolar Stepper Motors with 1/4 Inch shafts on both ends, nema23 mounting holes
(1) 40V 400W Power Supply
(1) DB25 Male Breakout Board (BOB)
(2) 24VDC Fans with finger guards
(1) DC-DC Converter
(1) AC Power Switch
(1) IEC AC Power Inlet connector
(1) IEC AC Power Cord
(1) 3' 25 Conductor Parallel Port Cable
(1) Rubber Grommet

Important NOTE:If you plan on using the Tote configuration as shown below, a 3rd internal fan to blow directly over the drives is required (specifically the left most X and Y drives shown in the PDFs linked below, as those drives are not directly in the line of intake air flow). Additional 24V fans are available on the accessories page.

Runs with Mach3/4, MachineKit and other STEP/DIR based controllers (UC100 & Smoothstepper).

Read ALL of the information on this page before purchasing. If you have questions, send an e-mail, but if the answer is already here on the page, there will be no e-mail reply.

Four 4M x 22mm Flat head screws are also include (not shown in picture). These can be used to fasten the power supply to a 3/4 Inch piece of plywood (not supplied). The power supply is a 40V power supply. This is the maximum voltage level of the drives. Voltages above this amount can cause the drives to go in to a shut down mode. Voltages of greater than 40V can occur during rapid deceleration of one or more motors, thus the suggested setting for the power supply is 38V. There is a potentiometer on the power supply that can be adjusted to set the supply to 38V.

This system entails wiring up 120VAC power, which if mishandled can cause injury, fire or death. If you are, or feel you may be, unqualified to complete the assembly operation, you should seek qualified help, or purchase the unit at such a time that qualified help becomes available.


Additional items you will need (not included with the system kit), available from most home improvement stores, ebay, amazon, internet,etc.:

18 AWG 4 conductor stranded copper cable (Sound & Security Cable)

16 AWG Stranded Hook Up Wire (Red)

16AWG Stranded Hook Up Wire (Black)

16AWG Stranded Hook Up Wire (Green)

Spade Terminals for 14-16 awg

.25" Quick Disconnect Terminals for 14-16 AWG


5 Gallon Storage Tote ~12W x 16L x 8H (Optional Enclosure) (Home Depot version shown)

8-32 1.25 inch long Machine Screws and 8-32 Nylon Locking Nuts (for fans)

'L' Brackets for mounting fans next to drives(see more on this below).

6-32 Pan Head Sheet Metal Screws (for fastening the drives to a plywood base)

6-32 Machine Screws and Nuts for mounting IEC AC inlet

Heat shrink Tubing for Motor and shield wiring

22 AWG stranded Red and Black wire to connect the DC-DC converter, and to wire up the STEP/DIR signal wiring.

22 AWG Stranded Hook Up Wire (Green) for cable drain/ground wires.

Weather Stripping for around fan install if using storage tote

Hot Melt glue and/or Double Sided Foam Tape to hold down DC-DC voltage converter.

8 3/4 X 12 1/2 X 3/4 Plywood for mounting base.

You will also need some tools: wire cutters, wire stripper and tools to crimp the terminals, screw drivers, a utility knife, and a multi-meter(volt meter). You will need a soldering iron and solder to wire up the DC-DC converter.
More assembly information coming soon.......

An assembled motor cable set for the system kit is available, click on picture below:
CableSet


Fan Wiring

The IN+ (RED) and IN-(BLACK) side of the DC-DC power supply will get wired to the AC-DC Motor Power Supply (+V) and (-V) Terminals respectively. The OUT+ will get soldered to the RED wires of the fans, while the BLACK wires of the fans will get soldered to the OUT- terminal. The white connectors on the fans can be simply cut off and wires stripped of insulation for soldering. The DC-DC power supply can mount on top of the motor power supply. You can use thick double sided foam tape for best results. Make sure the DC-DC Power Supply is firmly attached with the tape, and make sure that the DC-DC Power is isolated from the metal case of the motor power supply (no electrical contact between the DC-DC power supply and the metal case of the motor power supply). A short can blow-up the DC-DC power supply. Alternatively, the DC-DC supply can be mounted on the plywood base. The DC-DC power supply needs to be set for 24 volts on the output so the fans can be properly powered. Use a small screwdriver to adjust the blue potentiometer to get the output at 24 Volts when the input is powered with the motor 40VDC.


Example AC Power Wiring:


Right Click on image then click view image to see larger image.
Use two smaller sections of BLACK and RED 16 AWG wire, about 3 to 4 inches long with quick disconnects on each end, to connect the IEC Power connector to the power switch. The RED wire should connect to the left hand terminal when looking at the back of the IEC connector. There is a faint 'L' embossed in the plastic next to the connector. The BLACK wire will connect to the terminal with the 'N' embossed next to it. The Red and BLACK wires will connect to the 2 lower terminals of the power switch (it will look like the upper two have been cut off). Finally the Green wire has a quick disconnect and a spade terminal and should be made 9 inches long. It will connect directly from the earth GND of the power supply directly to the lower middle terminal of the IEC connector.

Using two quick disconnect and two Spade connectors and about 12-15 inches of both the RED and BLACK 16 AWG wire (longer may be easier for installation in an enclosure), make an extension that looks the the top cable shown above. This will connect the power switch to the AC side of the power supply. This cable will connect to the Middle two spade connectors on the power switch. Make sure to match color so that RED is on one side and BLACK on the other. The RED wire from the switch will go the 'L' terminal on the power supply and the BLACK wire will go to the 'N' terminal on the power supply.

Finally, the Green wire connects to the earth ground of the supply (which looks like an inverted 'T' with lines underneath it to the middle terminal on the IEC connector (embossed inverted 'T' symbol next to it as well.

When mounting the AC power switch, the AC input wires should be oriented to the bottom half of the switch, while the output to the power supply will be in the middle. This will make the switch be ON when the rocker is pressed in to the upper orientation when viewed from the switch face.

Always check that your crimp connections are secure by tugging on the wire and the connector before installation.

BOB to Drive Wiring
Pins 19-25 are Signal Ground connections.
There is a connection labeled GND on the BOB. This is NOT a signal ground connection, it connects to the DB25 metal shell.
On the following lines, the (+5V) is labeled on the drive. The input should actually be connected to the output of the parallel port STEP/DIR signals (pins 2-9), while the PUL -(PUL) label is connected to one of pins 19-25 of the BOB for GND.
BOB Pin Number
Pin 2 = X STEP drive label: PUL + (+5V)
Pin 19-25 PUL-(PUL)
Pin 3 = X DIR label DIR+ (+5V)
Pin 19-25 DIR-(DIR)
Pin 4 = Y STEP drive label: PUL + (+5V)
Pin 19-25 PUL-(PUL)
Pin 5 = Y DIR label DIR+ (+5V)
Pin 19-25 DIR-(DIR)
Pin 6 = Z STEP drive label: PUL + (+5V)
Pin 19-25 PUL-(PUL)
Pin 7 = Z DIR label DIR+ (+5V)
Pin 19-25 DIR-(DIR)
Pin 8 = A STEP drive label: PUL + (+5V)
Pin 19-25 PUL-(PUL)
Pin 9 = A DIR label DIR+ (+5V)

Pin 19-25 DIR-(DIR)
For software setup: The STEP signals are ACTIVE HIGH.
The ENA+ and ENA- connection on the drive are for active HIGH enable. The drive will be active by default, unless +5V is connected to the ENA+ and GND is connected to the ENA- terminals.

SW4, SW5 and SW6 on the drive should be set to the 'OFF' position which is in the 'UP' position on the drive.



Right Click on image then click view image to see larger image.
Wiring (From the top of the drive down):
RED = +V from Power Supply
BLACK = -V from Power Supply
--
Green = to Motor GREEN
Black = to Motor BLACK
White = to Motor BLUE
Red = to Motor RED
--
Red = to BOB STEP terminal (X-2, Y-4, Z-6, A-8)
Black = to BOB signal ground terminal (19, 20, 21, 22, 23 ,24 or 25)
Red = to BOB DIR terminal (X-3, Y-5, Z-7, A-9)
Black = to BOB signal ground terminal (19, 20, 21, 22, 23 ,24 or 25)
--
ENA+ = Unused
ENA- = Unused

BOB Pinout configuration

Right Click on image then click view image to see larger image.

Drive Power Connector Setup

Right Click on image then click view image to see larger image.
Step 1) Strip Gray PVC insulation and remove foil shield. Cut drain wire short as shown. Pre-tin (solder) the drain wire.
Step 2) Solder a 22 AWG Stranded wire (approx 4-6 inch long) to the drain stub wire after placing heat shrink tubing over cable.
Step 3) Shrink the tubing and then strip the cable wires for the screw terminal connection.
Step 4) Connect the motor cable as shown to the drive terminal block. The power connections will also be connected as shown.
Step 5) Solder all four motor earth ground drain wires together to a single 14 AWG wire and use heat shrink tubing to insulate the solder joint. The other end of the 14 AWG wire will get a spade crimp terminal. This will be connected to the power supply earth ground terminal (inverted 'T' with lines underneath, next the the 'N' AC connection. The earth ground wiring is not strictly mandatory, but will help reduce stepper motor drive EMI (electromagnetic interference - static noise on AM radio). If the shield ground wire is not used, it should be insulated under the heatshrink to prevent it from shorting out other connections.


Mounting the connection hardware in the user supplied storage tote (Home Depot tote example):
Click on picture for printable PDF version

If you use the 5 gallon Home Depot Storage Tote, you can use the following outline as a guide to install the BOB, Power Inlet, Power Switch, Grommet and the Inlet fan. Use only the fan section of the picture on the other side of the tote to mount just the Exhaust Fan.

Mounting the connection hardware in the user supplied storage tote (Home depot tote example):
Click on picture for printable PDF version


Right Click on image then click view image to see larger image.
Mounting example for drives, power supply and fan.

-- Additional Important Notes --

(1) The drives have opto isolation built in to them to isolate the high power side (motor) from the logic side.

(2) If the drives are mounted in 'open air', one of the fans should be placed to blow over the X and Y drive heat sinks, while the other fan should be placed to blow over the Z and A drive heat sinks. If the tote configuration shown on this page is used, a 3rd fan (purchased separately - see accessories page) must be used to blow air over the X and Y drives, and optionally a 4th fan for the Z and A drives, using the 2 fans that come with the kit for intake and exhaust from the tote enclosure.

The fans have an intake and exhaust direction. For tote enclosure, one fan should be installed to bring fresh air in to the enclosure, while the other fan should be installed to exhaust the warm air from inside the enclosure to the outside.

Proper operation of the kit requires adequate cooling of the drives. Keep the unit out of areas where dust can accumulate on the fans or the drives. Dust can get inside the fans and slow them down or even cause them to stop, thus inhibiting proper drive cooling. The user should perform occasional preventative maintenance by cleaning any dust from the fans or drives.

(3) The DC-DC converter should be set for 24V so the fans can operate at the correct voltage. This should be set after setting the drive power supply to 38V, but before attaching the power to the drives. The DC-DC converter will power 4 of the 24V fans with no problem.

(4) The recommended 18-4 wire has a drain ground wire and foil shield wrapping. The drain ground wire should be connected to earth ground at the drive end. The shield wire from each of the 18-4 motor cables should extended with green 22 AWG wire and all extensions should be tied together and connected to the earth ground of the power supply. Then the connection should be insulated with heat shrink tubing.

(5) Unused I/O on the BOB can be used for limit switches, STOP switches, touch probes, etc. as controlled by the software. See the software instructions for more information on how to set up the various other I/O that can be attached to the BOB. Other I/O are not associated with the operation of the kit.

(6) All drives are tested before they ship. If you do not get motor response to your CNC software stimulus, check the CNC software manual for trouble shooting, as it will be software/parallel port/step pulse generator related, and not related to the functioning of the motor drive kit.

(7) The drive and other circuitry are susceptible to over voltage conditions. Grounding the shield in the motor cable at the drive end, while the motor end is left 'floating' can help dissipate high voltages that might be introduced to the cables from external sources, but care should still be taken so that high voltages generated from things like vacuum (dust collection) systems are properly handled (e.g. a grounded bare flexible braided copper wire inside the vacuum hose) to mitigate high voltages sources.

(8) The four screws for the power supply are specified for use with 3/4 inch plywood so that extra screw length does not penetrate further inside the power supply which could happen with thinner base plywood. The counter-sink in to the wood should only be deep enough to allow the head of the screw to lie flush with the surface of the plywood. Additionally, the spacing of the BOB on the mounting diagram is set based on using 3/4 inch plywood (when mounting in 5 gal. tote). Before mounting the power supply to the plywood make sure the input voltage select switch on the side of the supply is set for 110/115 VAC and not for 220/230VAC.

Before applying power to the system, it is imperative that all wiring be double checked.
(9) The motors will make a slight humming or buzzing sound when idle. That is normal.
(10) Mach3/4, MachineKit and other software packages parameter setup (max speeds and accels) depend on your specific machine. You must determine them empirically. No generic setup files are provided. Example connections for STEP/DIR pin settings is given above with the BOB. This is a suggestion but not required, as the software settings determine the actual pinout usage that the BOB can be wired to.

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