Wire Converter/Fan
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Setup Power chassis
Mount Chassis
Mount Aux Panel
Mount Power supply
Power Supply no Chassis
Power Supply with Chassis
Power Supply with Chassis & Aux
Mount AC Relay
Mount DC Converter
Mount E-Stop
Mount Limit Switchs
Mount Stepper Motors
Mount Cooling Fan
Wire DC Converter to Power Supply
Wire JK02 to DC Conv
Wire DIV268N to Steppers
Wire JK02 to DIV268N
Wire DIV268N to Power
Wire Steppers
Wire E-Stop to JK02-M
Wire Limit Switches
Wire Limit Switches to JK02-M
Wire Converter/Fan
Mach3 EStop/Limits for JK02
Mach3 Pins/Ports JK02-M5

 

 

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Connecting the Fan and DC Converter and to the Power Supply

These instruction will explain how to connect the Cooling fan to The DC to DC converter and then the converter to
the 24V Power Supply

As nearly everything in your enclosure produces heat, particularly the TB6560 Driver board and 24V Power Supply, it is important a Cooling
Fan be installed. However, the Cooling Fan runs on 12V DC, but the Power Supply is 24V. This is where the DC to DC Converter comes in to
use. The DC Converter can transform any power source between 12V and 48V DC to 12V DC at a steady current of 3 amps. The Converter
can also be used to power other 12V items such as gauges or fluid pumps (up to 3 amp (combined)).
 

 

 

Warnings

AC Mains Power can kill or seriously injure

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

Never make changes to your equipment while it is powered up as it could permanently damage it

 

 

Parts Required

Supplied Parts

1 x Mounted Power Supply

1 x Mounted DC - DC Converter

1 x Mounted 120mm Cooling Fan

2 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

Soldering iron (optional)

 

 

Parts Overview

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

 

12V DC Cooling Fan

  1. Motor Mount
  2. Fan assembly (center hub)
  3. Fan housing
  4. 4.5 mm Mounting points
  5. DC wiring

DC to DC Converter

  1. Terminal 1 - DC+ 12V to 48V Input
  2. Terminal 2 - DC- Common Ground to all circuits (Terminals 2 & 3 on DC Converter Type 1)
  3. Terminal 3 - DC+ 12v Output (4th terminal on Type 1)
  4. 3mm Mounting points
  5. Heat sink

 

 

Assembly/Installation process

Make sure your power is not on, unplug the lead from the wall socket.

 

Wiring the Cooling Fan to the DC Converter

The first step is to remove the Molex plugs, cut the fans DC wires as close to the Molex plugs as possible. The plugs can be discarded

 

Strip back the insulation approx 6mm and give the wires a twist to bind the loose fibers.

 

With a Philips screw driver loosen of terminals 2 and 3 on the DC Converter.

 

Insert the DC+ wire from the Cooling fan into Terminal 3 (12V DC+ Out) on the DC Converter and tighten screw.

Now plug the Terminal block into pins 16 and

 

Insert DC- wire from the Cooling fan into Terminal 2 (DC- Common) on the DC Converter.

The Fan is now wired to the DC Converter

 

Wiring the DC Converter to the Power Supply

Using the same method for measuring wires all throughout these instructions, run a black (DC-) wire from Terminal 6
(DC- Out) on the Power Supply to Terminal 2 (Common DC-) on the DC Converter. Allow for an additional 10mm at the
Power Supply and 6mm at the DC Converter. Strip back the insulation 10mm at one end and 6mm at the other.

 

Now run a Red (DC+) wire from Terminal 3 (DC+ Out) on the Power Supply to Terminal 1 (DC+ In) on the DC Converter. Allow
for an additional 10mm at the Power Supply and 6mm at the DC Converter. Strip back the insulation 10mm at one end and
6mm at the other.

 

Attach a Fork terminal to the 10mm stripped end of each wire.

 

With a Philips head screwdriver loosen off terminal 3 on the Power Supply and terminal 1 on the DC Converter.
Attach the fork connector on the Red (DC+) wire to Terminal 3 on the Power Supply and tighten screw. Insert the
stripped end of the same wire into Terminal 1 on the DC Converter and tighten screw



 

Now loosen off terminal 6 on the Power Supply. Attach the fork connector on the Black (DC-) wire to Terminal 6 on
the Power Supply and tighten screw. Insert the stripped end of the same wire into Terminal 2 on the DC Converter
(The DC- wire from the Cooling fan should already be attached to this terminal, I know it seems strange but yes both
the 24V and 12V system share the same "Negative" terminal), tighten screw.

 

The Cooling Fan and DC Converter are now wired.

 

It's now time to connect the power supply to power and test the Cooling Fan. 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. Turn on the wall socket and turn on your power switch. The Green LED on Power supply should be
on and the Cooling Fan should be rotating (Cooling fan has blue LED's which should also be illuminated).

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

Image of Cooling Fan LEDs taken during testing (10 units pictured)

 

 

Next Step

You are now ready to move onto the next step:

TBA

 

 

 

 

   

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This site was last updated 02/08/14