Wire E-Stop
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Mount TB6560
Wire TB6560 to Power Sup
Wire AC Relay
Wire E-Stop
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Mach3 EStop/Limits TB6560
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Wiring the E-Stop button

These instructions will explain how to wire the E-Stop Button to the TB6560 driver board and how to wire the
E-Stop button as a hard off for the AC Relay.

The Emergency Stop button supplied with your kit has 2 circuits that act independently of each other but are triggered by the same button push.

The first circuit on the button is designed to bring all of your CNC components to a complete stop. It is not wired directly to any components other than the TB6560 Driver board. The driver TB6560 Driver board sends a signal back to the software and your software will stop all devices; Stepper motors, Router, Vacuum, fluid pumps, etc that are connected to it. The main advantage to using an E-Stop button is that it is not a "hard off" like flicking a power switch, once you have cleared the issue you can resume activity where the machine was stopped.

The second circuit is for a "hard off" type scenario and would be connected to device that don't really have a resume position, devices like spindle motors, vacuums, lights and pumps and "NOT" the PC, Driver board or other bootable/software controlled devices. The intended use for this in your kit is to run the AC Relay where these devices would expect to be connected. It is in a way a replication of the "software" off function, however it will function even if the PC is off / software isn't loaded. This is useful during booting of your PC as sometimes the TB6560 Driver board can activate unexpectedly while not under control of Mach3 or other software.

 

Warnings

AC Mains Power can kill or seriously injure you

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

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

 

 

 

Parts Required

Supplied Parts

1 x Mounted TB6560 Driver board

1 x Mounted AC Relay

1 x Mounted E-Stop Button

1 x Limit Switch cable

4 x Fork terminal

1 x Rail connector (Optional but recommended)

 

Parts to be sourced

No additional parts required.

 

Recommended tools

Wire stripper

Wire cutter

Crimping tool

Philips head screwdriver

Soldering iron (optional)

 

 

Parts Overview

TB6560 Driver board

  1. Pin 1 - Relay 12/36v DC + in (MIN)
  2. Pin 2 - 12/36v DC -
  3. Pin 3 - Relay 12/36v DC + out (MOUT)
  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

 

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

 

Emergency Stop Button

  1. Terminal 1 (Normally Closed circuit in)
  2. Terminal 2 (Normally Closed circuit out)
  3. Terminal 3 (Normally Open circuit in)
  4. Terminal 4 (Normally Open circuit out)
  5. Normally Closed Circuit
  6. Normally Open Circuit
  7. Switch Assembly
  8. Inner retaining nut
  9. Rubber seal
  10. Outer retaining nut
  11. Mushroom button

 

 

 

Assembly/Installation process

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

 

Connecting the E-Stop Button to the TB6560 Driver board.

Lay out the Limit cable with the Pug to the left and the black lead closest to you. The black lead is Pin 5 and is
the common wire (DC-) for the other 4 wires. Orange is Pin 1, Yellow is Pin 2, White is Pin 3 and Red is Pin 4.
Pins 1 trough 4 are configurable and can be set to any "Input" signal your require. In this example we are going to
use Pin 4 (Red) as our E-Stop signal and we will need Pin 5 (DC- Common) to complete the circuit .

 

Strip the red and black wires back approx 6mm and give them a twist to bind any loose strands

 

Attach a fork terminal to the red and black wires either by crimping or soldering (preferred).

 

Insert the Limit cable into the connector on the TB6560 Driver Board labeled as "21" on the Driver board diagram,
the pug should only fit one way with the Black lead (Pin 5) facing the outside.

 

Allow the unused leads to hang over the back of the board.

 

Looking at the E-Stop button we can see one side is green and the other is orange. The green side is the "Normally
Open" circuit, this means it usual state is "off", and if the button is pressed it will become "on". This is the side we
will be wiring to.
 

 


Loosen off Terminal 3 on the E-Stop button and insert the wire from Pin 4 (Red) on the Limit cable into Terminal 3
and then re-tighten

 

Loosen off Terminal 4 on the E-Stop button and insert the wire from Pin 5 (Black) on the Limit cable into Terminal
4 and then re-tighten

 

In this example the Fork Connectors have been bent 45o to make them fit better with the shape of the E-Stop
button terminals. 

 

To plan ahead for your Limit Switches (as they use the same common wire) you should get the Common wire (Pin 5
- Black) on the Limit cable to pass through a vacant position on a Rail Connector and then to Terminal 4 on the E-Stop
button. (wiring Limit Switches explained further in "Wire Limit Switches").

 

 

Wiring the E-Stop button as a hard off for the AC Relay

Locate the DC+ wire (Red) that runs from Pin 3 (DC+ MOUT) on the TB6560 Driver board to Terminal 3
(DC+ In) on the AC Relay. As per previous instructions this wire should be 50mm (approx) longer than is
required. Find where that wires central point is over the E-Stop Button and cut it with your wire cutters.

 

As per previous steps strip back 10mm of each of the wires. Attach a fork terminal to each side (either
by crimping or soldering).

 

Loosen off the screw for terminal 1 on the E-Stop button. Attach the wire coming from Pin 3 (MOUT) on the TB6560
Driver board to terminal 1 (DC+ in) on the E-Stop button and tighten screw.

 

Loosen the screw on Terminal 2 of the E-Stop button and attach the wire coming from Terminal 3 (DC+ in) on the
AC Relay and re-tighten the screw.

 

The relay is now wired through the E-Stop Button. At anytime while the E-Stop button is depressed the current
flowing from the TB6560 Driver board to the AC Relay will be cut, the AC Relay will then cut power to any
attached devices. This action is independent of the the E-Stop signal that will be sent to any software via the
parallel cable attached to the TB6560 Driver board.

 

 

Supplementary Images

No additional images

 

 

 

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