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110V Cooling Fan

Use the one I own

Power Supply
Antek AN 4228
Gecko power supply (78 VDC & 39 VDC)
Antek AN 0209
Auxilary power supply (9 VAC & 24 VDC)
Specs
Antek page
Bridge Rectifier
here
Marlin P Jones
400PIV 25Amp Bridge $2.79
400PIV 1.5AMP Bridge 39 cents.

E-Stops on Gantry & Y-Car


WEG 22mm Non-metallic, Single Contact Block, 1 N.C. Price: $2.00 each (needs "operator" and enclosures wit
Spec
FactoryMation page
E-Stop Monitoring Relay, ES Relay
24VDC SPDT RATED 6AMP AROMAT

here

On / Off Pushbuttons
WEG 22mm Non-metallic, Double Pushbutton Operator w/ center illumination lens , IP40, "I / O", Price: $7.00
Spec
FactoryMation page
Disconnect
ENSTO Rotary Load Break Disconnect Switch, 3 Pole, 600V, 40A Price: $16.50 (needs handle & accesories)
Spec
FactoryMation page
KSR.40
KSH48RY
KK31.200C
Contactor
TECO IEC Contactor - 16A, 120VAC / 60Hz Coil, 3 Pole 600V, 1 N.O. Aux Price: $12.00
Specs
FactoryMation

Router Relay, Dust Collector Relay, Vacuum Relay


Switched directly by 5V TTL from PMDX-122 breakout card. Do not connect relay "coil" or input to the mains ci
CONTACTOR 24 VDC 3 POLE/35A P&B

Wire Duct

WIRE DUCT GREY 1PCS 1.0 X 1.0 IN 2M WITH COVER, Price $13.00
T1-1010G-1
www.automationdirect.com

Capacitor/s
4 x 10,000 uf, 100 Volt Electrolytic capacitors, Ebay, $41 ($10.25 ea.) including shipping

110V Router
The parts above assume the router draws no more than 15 Amps constant and 25 Amp on starts

Sean's Connector Preferences


Modular pins connectors I like (in no particular order)
- Nema L series twistlocks...many configurations, great current capacity..but large in form factor. I used these
- Amp crimp pin for the 3 to 28 pin connectors
- XLR, because they are metal and last and carry "a decent amount of current"
- Molex - if the twist connection type
- phoenix 4 and 5 pin (like the modbus and device net used on PLC networks for machine control

Neutrik connectors used by JR 10 pcs NC4FX and 10 pcs NC4MX


http://www.markertek.com/p/fullpage.php?page=021

Terminal Blocks for connecting from PCBs


Phoenix Contact 2-position stackable PCB terminal block, 0.2 inch Ordered from MemoTronics on 12/14/08
Fuse Holders
3AG FUSE HOLDER
5 Volt Relay to activate the Router, Dust Collector and Vacuum Hold-Down CONTACTORS from the P
5 Volt Relay, 1 Form C, Ordered from MemoTronics on 12/14/08

Ferrules used by Sean, Kit, $28.50 plus $9.40 shipping


specs
Ferrules Direct page
Harbor Freight racheting crimper
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=93977
Gerald's post on cabling
4
1
1
1

cables, 4 core, 1.0mm 2[18 AWG] for the 4 steppers


cable, 4>3 core, 1.5>(2.0)mm2 [14 AWG] for the spindle main>router motor. (15 amp?) 2-core if router ha
cable 4 core, 0.5mm2 [21 AWG] for the spindle fan and thermistor >
cable 7 core, 0.5mm2 [21 AWG] for input/output signals from the breakout card (not all cores are used yet)

1 cable 4 core, 0.5mm2 [21 AWG] for 220V power/control. (2 cores used for E-stop) (only 2 cores are needed,
I have just counted the strands in some Lapp lflex Classic that are here at home:
1.5mm2 30 strands (16AWG)
0.5mm2 16 strands (21AWG)
Their spec, from the links above, says bend radius of 20x where there is movement and 6x for static. Maybe I

1.0mm
2.0mm
0.5mm
0.5mm

squared (18 AWG) 4 core - $1.44/foot


sqd (14 AWG) 3 core - $2.42/foot
sqd (21 AWG) 7 core - $1.55/foot
sqd (21 AWG) 2 core - $.93/foot

Doug Ford Cable Length Post


Z-axis motor - 18 feet 6 inches + distance to control box
Y-axis motor - 18 feet 8 inches + distance to control box
X-axis motor (front) - 16 feet 6 inches + distance to control box
X-axis motor (back) - 7 feet 6 inches + distance to control box
Router motor cable two core cables 18 feet 6 inches + distance to control box
- E-stop circuits. There are two E-stop switches under each E-stop operator

28
28
26
18

ft
ft
ft
ft

100

(or button). One switch is connecte

Both the 2 core and 7 core cables will be divided into three pieces:

The first cable will be 7 feet 6 inches long + the distance to your control box. That cable will run from the con
The second cable will be 9 feet long and will run from the E-stop/Pause/Resume box mounted on the gantry
The third cable will be 11 feet long and will run from the E-stop/Pause/Resume box mounted on the gantry o
Be sure you connect the E-stop switches in series

1st Factorymation Order


31.00 Terminal Blocks - 1 package of 100 pieces - Item# ER2.5beige
http://www.factorymation.com/s.nl/it.A/id.277/.f
12.00 I'm using CN-16-F6
http://www.factorymation.com/s.nl/it.A/id.90/.f
http://www.factorymation.com/s.nl/it.A/id.4517/.f?category=
6.00 Disconnect Handle - 1 each - Item# KSH48RY
5.00 Terminal Block End Plate - 1 package of 25 pieces - Item# EP2.5 - 10
http://www.factorymation.com/s.nl/i
2.50 Lamp Switch - 1 each - Item# BI DL
http://www.factorymation.com/s.nl?it=A&id=544&category=
5.00 Terminal End Bracket - 1 Package of 20 items - Item# ES1
http://www.factorymation.com/s.nl?it=A&id=326
http://www.factorymation.com/s.nl?it=A&id=252
15.00 Jumper Strips - 1 package of 5 pieces - Item# CC2.5/10
7.50 On/Off Green/White/Rep Operator - 1 each - - Item# BD
http://www.factorymation.com/s.nl/it.A/id.483/.f
2.50 Normally Closed Switch - 1 each - Item# BC01
http://www.factorymation.com/s.nl/it.A/id.538/.f?category=
2.50 Normally Open Switch - 1 each - Item# BC10
http://www.factorymation.com/s.nl/it.A/id.537/.f?category=
http://www.factorymation.com/s.nl/it.A/id.551/.f
2.00 Incandescent Bulb for WEG 22mm 130V
13.00 Steel Din Rail - 1 package of 5 items - Item# 35S-5
http://www.factorymation.com/s.nl?it=A&id=4227&categor
6.00 305mm Extension Shaft for Rotary Switch - 1 each - Item# KK31.305C (NOTE: You must trim to fit.)
http://www.factorymation.com/s.nl/it.A/id.4512/
23.00 Disconnect Switch 480V 60A Ensto - 1 each - Item# KSR 3.60/U
133.00 Sub-total
10.43 Shipping
143.43 Total
2nd Factorymation Order
22.50 Mushroom E-stop Operator - 3 each - Item# BEG
http://www.factorymation.com/s.nl/it.A/id.481/.f?category=
10.50 Resume Operator - 3 each - Item# BF2
http://www.factorymation.com/s.nl/it.A/id.475/.f?category=

10.50
15.00
15.00
36.00
109.50
8.00
117.50

http://www.factorymation.com/s.nl/it.A/id.476/.f?category=
Pause Operator - 3 each - Item# BF3
Normally Open Switch - 6 each - Item# BC10
http://www.factorymation.com/s.nl/it.A/id.537/.f?category=
Normally Closed Switch - 6 each - Item# BC01
http://www.factorymation.com/s.nl/it.A/id.538/.f?category=
22MM Pushbutton Plastic Enclosure 3 Button - 3 each - Item# 590.PRO3K-A http://www.factorymation.com/s.nl?
Sub-total
Shipping Guess?
Total

or" and enclosures with other "buttons" & switches)

, "I / O", Price: $7.00 Requires Contact Blocks (1ea BC10 and BC01 sold seperately) (Lamp block optional)

ndle & accesories)

r input to the mains circuit!

ORDERED

m factor. I used these for the Router and Dust collection on my box...See photo in post 92

TACTORS from the PMDX-122

p?) 2-core if router has only a 2-core cord.

ll cores are used yet)

ly 2 cores are needed, but you might not be able to get it)

6x for static. Maybe I went a bit overboard with my cables for this application? Cables are seldom discussed on all the CNC

ft

One switch is connected to a circuit that shuts off the contactor. You need a separate 2 core cable for this circuit. The othe

le will run from the control box through the X-Axis echain to the E-stop/Pause/Resume box mounted on the gantry on the
mounted on the gantry on the backside of the MM through one of the gantry tubes to the E-stop/Pause/Resume box mounte
ounted on the gantry on the backside of the MM through the Y-axis echain to the E-stop/Pause/Resume box mounted on th

tion.com/s.nl/it.A/id.277/.f?category=
nl/it.A/id.90/.f
nl/it.A/id.4517/.f?category=
w.factorymation.com/s.nl/it.A/id.1349/.f?category=
nl?it=A&id=544&category=144
tion.com/s.nl?it=A&id=326&category=
tion.com/s.nl?it=A&id=252&category=
CC2.5/101IMO
tion.com/s.nl/it.A/id.483/.f?category=
nl/it.A/id.538/.f?category=
nl/it.A/id.537/.f?category=
nl/it.A/id.551/.f
nl?it=A&id=4227&category=
http://www.factorymation.com/s.nl/it.A/id.4844/.f?category=5982
tion.com/s.nl/it.A/id.4512/.f

nl/it.A/id.481/.f?category=
nl/it.A/id.475/.f?category=

nl/it.A/id.476/.f?category=
nl/it.A/id.537/.f?category=
nl/it.A/id.538/.f?category=
w.factorymation.com/s.nl?it=A&id=4632&category=

scussed on all the CNC forums

or this circuit. The other switch is connected to a circuit that uses the PMDX breakout board to perform the stop. The wires

d on the gantry on the backside of the MM.


se/Resume box mounted on the gantry on the front side of the MM.
me box mounted on the car.

rm the stop. The wires for that circuit are part of the seven core cable. The other wires in this cable are for the pause and

are for the pause and resume circuits. Both the 2 core cable and the 7 core cables are the same length overall and may be

gth overall and may be routed along side each other.