Wire AC Relay
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Mount TB6560
Wire TB6560 to Power Sup
Wire AC Relay
Wire E-Stop
Wire Limit Switches
Mach3 EStop/Limits TB6560
Mach3 Pins/Ports

 

 

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Wiring the Relay to the TB6560

These instructions will explain how to wire the relay to the TB6560 driver board, Power supply
and Auxiliary Power Panel.

The TB6560 has an onboard relay switch, however, it is a DC relay and only capable of handling voltages
from 12V to 36V DC. This is fine if you are using a DC motor that falls between those voltages for your
spindle, but in most cases it is common to use a 240v AC router. In order to have your router controlled
by your software you will need to add an additional AC relay to your setup.

 

Warnings

AC Mains Power can kill or seriously injure you and those around you

DO NOT plug in your equipment while you are working on it

Never add or remove wires from/to your Breakout Board while it is powered up as it may permanently damage it

Never place your hand in live equipment that contains un-insulated or bare AC terminals and wires.

 

 

 

Parts Required

Supplied Parts

 

 

 

 

 

1 x Mounted TB6560 Driver board

1 x Mounted Power Supply

1 x Mounted Power Chassis

1 x Mounted Auxiliary Power Panel

1 x Mounted AC Relay

1 x Power lead

1 x 3 Pin Terminal Block

5 x Fork terminal

1 x DC Wiring set

 

Parts to be sourced

 

 

 

 

 

 

No additional parts required.

 

 

Recommended tools

 

 

 

 

 

Wire stripper

Wire cutter

Crimping tool

Philips head screwdriver

Flat head screwdriver (small)

Soldering iron (optional)

 

 

Parts Overview

TB6560 Driver board

  1. Pin 1 - Relay 12/36v DC + in
  2. Pin 2 - 12/36v DC -
  3. Pin 3 - Relay 12/36v DC + out
  4. Pin 4 - Z Axis A+ out
  5. Pin 5 - Z Axis A- out
  6. Pin 6 - Z Axis B+ out
  7. Pin 7 - Z Axis B- out
  8. Pin 8 - Y Axis A+ out
  9. Pin 9 - Y Axis A- out
  10. Pin 10 - Y Axis B+ out
  11. Pin 11 - Y Axis B- out
  12. Pin 12 - X Axis A+ out
  13. Pin 13 - X Axis A- out
  14. Pin 14 - X Axis B+ out
  15. Pin 15 - X Axis B- out
  16. Pin 16 - 12/36v DC - in
  17. Pin 17 - 12/36v DC + in
  18. Dipswitch bank 1 - X axis setting
    1. SW1 - Current setting
    2. SW2 - Current setting
    3. SW3 - Decay mode setting
    4. SW4 - Decay mode setting
    5. SW5 - Microstep Setting
    6. SW6 - Microstep Setting
  19. Dipswitch bank 2 - Y axis setting
    1. As per bank 1
  20. Dipswitch bank 3 - Z axis setting
    1. As per bank 1
  21. Emergency stop and limit switch connector
    1. Pin 1 - X Limit (configurable)
    2. Pin 2 - Y Limit (configurable)
    3. Pin 3 - X Limit (configurable)
    4. Pin 4 - E-Stop (configurable)
    5. Pin 5 - Ground (common ground for all pins)
  22. Display panel connector
  23. D-Sub 15 - Jog pendant Input connector
  24. D-Sub 25 - Parallel cable/PC input connector
  25. Axis activity LEDs
  26. TBA
  27. Cooling fan and Heat sink

 

Power Supply

  1. Terminal 1 - 24v DC + Out
  2. Terminal 2 - 24v DC + Out
  3. Terminal 3 - 24v DC + Out
  4. Terminal 4 - 24v DC - Out
  5. Terminal 5 - 24v DC - Out
  6. Terminal 6 - 24v DC - Out
  7. Terminal 7 - 240v AC Earth - In
  8. Terminal 8 - 240v AC Neutral - In
  9. Terminal 9 - 240v AC Live - In
  10. Power LED
  11. Minor voltage adjuster
  12. Power Supply input voltage selector 240v AC or 110v AC
  13. Cooling fan exhaust port

 

Power chassis

  1. Power Switch (installed in Chassis)
  2. Power Chassis
  3. Fuse Holder
  4. "Live" pin 240v AC
  5. "Ground/Earth" pin 240v AC
  6. "Neutral" pin 240v AC
  7. "Live" input pin(s) on switch, 240v AC
  8. "Live" output pins on switch, 240v AC

 

Universal Socket Panel

  1. AC "Live" pin (straight through front to back)
  2. AC "Neutral" pin (straight through front to back)
  3. AC "Earth" pin (straight through front to back)

AC Relay

 

  1. Terminal 1 - AC Live input (24v-380v AC)
  2. Terminal 2 - AC Live output (24v-380v AC)
  3. Terminal 3 - DC+ input (3v-32v DC)
  4. Terminal 4 - DC- input (3v-32v DC)
  5. Relay Mounting Points
  6. Activity LED
  7. Back plate / heat sink

 

Power cord

 

 

Required/Recommend Steps Before these instructions

Mounting Relay

Connecting Power supply via Power chassis with Auxiliary power panel.

 


 

Assembly/Installation process

Make sure your setup is turned off and the power lead is
not plugged into a wall socket!!

Reminder number 2

Make sure your setup is turned off and the power lead is
not plugged into a wall socket!!

 

Connecting the AC Relay between Power Chassis and Auxiliary Power Panel

During the "Wiring Auxiliary Power Panel" instructions you where asked to add an additional 50mm
of wire, this was more than you needed but will give you room to move during the following
instructions. Also, during the "Mounting the AC Relay" you needed to make sure that terminals 1
and 2 on the Relay intersected with the Auxiliary Power Panel's "Live" wire at some point. We are
now going use those two points.

 

Locate the live wire that runs from "Live" out pin 2 on the switch installed in the Power Chassis to the "Live"
input pin on the Auxiliary Power Panel. Find where that wires central point is over the Relay and cut it with
your wire cutters.

 

As per previous steps strip back 10mm of each of the live wires. Attach a fork terminal to each side (either
by crimping or soldering). Loosen off the screws for terminal 1 and 2 on the AC Relay. Attach the wire
coming from the Power Chassis to terminal 1 on the AC Relay. Attach the wire going to the Auxiliary Power
Panel to terminal 2 on the AC Relay. Tighten the screws.

 

Connecting the AC Relay to DC- on the Power Supply

The next step is to connect the AC Relay Terminal 4 (DC-) to Terminal 5 (DC-) on the Power
Supply. Using the same method as we've used in the past, run a wire from the Power supply's
terminal 5 to the Relays terminal 4. Allow 10mm extra at each end of the wire, and cut.

 

Strip back each end of the wire approx 10mm. Attach a fork terminal to each end (either by crimping or
soldering). Loosen off terminal 5 on the Power supply and terminal 4 on the Relay. Insert the fork terminals
into terminal 5 on the Power supply and terminal 4 on the Relay and tighten.

 

Connecting the AC Relay to DC+ on the Power Supply via TB6560 internal relay

Now the AC Relay needs to be wired through the TB6560 relay and to DC+ on the Power Supply. First we
need to create a wire from Terminal 2 (DC+) on the Power Supply to Pin 1 (MIN) on the TB6560 and then
a second wire from Pin 3 (MOUT) on the TB6560 to Terminal 3 (DC+) on the AC Relay. Measure these 2 wires
in the way we have all the way through these instructions, remembering to add 10mm. Please note, at a
latter stage during these instructions you will have the option to use the second "Normally Connected" circuit
on the Emergency Stop button to turn this relay off and on, if you are going to choose to use this option
please add an additional 50mm to the wire going from the TB6560 to the AC Relay.

 

 

The next step is to connect the stripped wires to the 3 wire Terminal block. Use a small flat head screwdriver
to loosen the 2 end screws on top of the block (the centre screw not used), as you loosen the screws you might
notice the terminals inside are not opening. This is because they are spring loaded, push down with screwdriver
and you should see them open. Place the block in front of you with the screws facing upward, the connector
pins should be pointing to your left and the open terminals to the right. Insert the wire that will lead to the
Relay in terminal furthest from you (should line up with pin 3 on the TB6560) and tighten the screw. Now place
the wire that will run to the Power supply in the terminal closest to you (this will line up with pin 1 on the
TB6560) and tighten. Crimp or solder a fork terminal to the remaining ends.

 

Plug the 3 Pin Terminal block into pins 1, 2 and 3 on the TB6560 driver board. Pinch the top of the connector
and the underside of the board between your fingers as you insert the Terminal, this is to stop you from pulling
the connector away from the board as the fit might be tight. The small fins on the top of the Terminal go
over the top of the connector.

 

Loosen off the terminal screws on Terminal 2 (DC+ out) on the Power supply and Terminal 3 (DC+ In) on the
AC Relay. Run the wire connected to Pin 1 on TB6560 to Terminal 2 on the power supply and tighten the screw.
Now run the wire connected to Pin 3 on the TB6560 to Terminal 3 on the AC Relay and tighten screw.

 

It's now time to connect everything up. Make sure the Power switch on the Power chassis is in the "Off"
position. Insert the power lead into the chassis. Turn off your wall socket and plug the power lead in.

 

The AC Relay is now connected and ready for it's initial test while not under any load. Place your enclosure
on a bench near the wall socket. Do not hold the enclosure during testing. Turn on the wall socket and turn
on the chassis power switch. The default setting for the TB6560 relay is "ON" this should also translate the the
AC Relay being on. To check this the Relay has an Activity LED on it's front panel (Item 6 on the AC Relay Tech
diagram). The power LED should now glowing red to indicate it is on.
 


 

Observe the unit for a minute or so to make sure nothing is wrong, Turn it off at the switch then the power point
and unplug it from the wall. Always unplug your power supply when not in use. After turning off your power supply,
please wait 60 seconds before turning it back on.

 

 

Supplementary Images

No additional images

 

 

 

Next Step

You are now ready to move onto the next step:

Connecting Emergency stop button to TB6560 Driver Board

 

 

 

 

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This site was last updated 02/08/14