Power Supply with Chassis & Aux
Home
Up
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

 

 

Hi, if you find these instructions helped with your CNC project, please consider
making a donation to help keep this site going and growing.
To make a contribution click anywhere here

 

Setting up the power supply

Connecting Power supply via Power chassis with Auxiliary power point option

This step explains how to connect the mounted Power supply to the mounted Power chassis and
Auxiliary power panel. The Power chassis provides fuse protection as well as the functionality of
an on/off switch and a means to disconnect enclosure without unscrewing terminals. Adding the
Auxiliary power panel will also allow you to connect a second device off your CNC enclosure,
devices such as a router (intended), vacuum, fluid pump, etc..

 

 

Warnings

  1. Mains AC power can Kill or seriously injure you and those around you
  2. Do Not connect your power cable to power while assembling/repairing your equipment
  3. Not ensuring the Power Supply is set to 240V before plugging it in will permanently
    damage it (see instructions below)

 

 

 

 

Parts Required

Supplied Parts

1 x Mounted Power Supply

1 x Mounted Power Chassis

1 x Mounted Auxiliary Power Panel

3 x Fork terminal

4 x 4.8mm Spade terminals and covers

3 x 6.3mm Spade terminals and covers

1 x AC Wiring set

 

Parts to be sourced

1 x Power lead

 

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

 

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)

 

Power cord

 

 

Assembly/Installation process

Make sure your power lead is not plugged into a wall socket (I know, but I have to say it)

 

 

Setting the input Voltage switch

Please check the voltage selection switch is in the right position.

 

Make sure the switch is set to 240V and not 110v. If it is set to 240v, you will be
able to read it on the switch, if the switch reads 110v please use a screwdriver
and push the switch to the right until the switch reads 240v. If it's set to 110v
and is switched on it will permanently damage the power supply. (the switch
may say 220v or 230v depending on the version of the power supply but will
work with 240V)

 

 

Connecting the Power Supply and Auxiliary Power panel to the Power Chassis

Roll out your AC wire kit so it is flat. Make sure you have a Live (brown), Neutral (blue)
and Ground (green or green/yellow) wire. It is highly recommended you use the correct
wire colour for each step, this will avoid confusion at a letter stage or avoid placing
someone else's life in danger should you sell or pass your machine on.

 

The next step is slightly more complicated as we don't know the actual length of wires
need to connect the Power Supply and Aux Power panel to the Power chassis (as everyone's
enclosure will be different). So we are going to have to measure them individually. The first
step is to take the "Live" (brown) wire and place one end of it at the base of the first "Live"
power out pin on the switch installed in the chassis (refer to Item 8 on the Power chassis
diagram for your switch type). For Switch type 1 please use the lower output pin.

 

Run the wire back to terminal 9 (Live AC input terminal) on the power supply
(please refer to the
Power Supply diagram). Allow the surplus wire to hang over
the top or back of the power supply.

 

Measure forward along the wire an addition 10mm from the center of Terminal 9
on the Power supply. This will provide some additional wire so wires are not taut
when installed. Taut wires (wires under strain) are likely to come loose or break
in environments where vibration, movement or heating and cooling is a factor.

 

Cut the wire at this point. The wire from the switch to the Power supply should now
be set to one side for latter use (attaching spade and fork terminals). The additional
wire is now used to run from the Chassis to the Aux panel.

 

Now we have a length of wire to connect the Power supply to the Chassis we now need to
get a length to go to the Aux panel. It is the same process, except we are going run from
"Live" output pin 2 on the back of the switch. Take the remaining "Live" (brown) wire and
place one end of it at the base of the second "Live" power out pin on the switch installed
in the chassis (refer to Item 8 on the Power chassis diagram for your switch type). For
Switch type 1 please use the Upper output pin.

 

Run the wire across to the Live (AC input) terminal on the Aux Panel (please refer to item "1" on
the
Aux panel diagram). Allow the surplus wire to hang over the top or back of the power supply.
In this example the wire is just run straight across, however you may want to consider using cable
ties or mounting clips to direct/tidy the path this wire (and other wires) takes. Add these items
first or calculate their positions and run the wire through them.

 

If you are intending to add the Relay in to this circuit latter on you will need to add an
additional 50mm to this length, if not 10mm will be sufficient.

 

Cut the wire at the desired point. The wire from the switch to Aux panel should now be set to
one side for latter use (attaching spade and fork terminals). The additional wire is no
longer required and can be put away.

 

You now need to repeat this process with the Neutral (blue) wire to get it's lengths.
Runs this wire from the Neutral output pin on the back of the Power chassis (refer
to Item 6 on the Power chassis diagram) to terminal 8 (Neutral AC input terminal) on
the power supply (please refer to item 8 in the
Power Supply diagram). Ensure you
measure the additional 10mm (approx) of wire. Once cut put a side with the other
wires.

With the remaining Neutral (blue) wire run a second length from the Neutral output pin
on the back of the Power chassis (refer to Item 6 on the Power chassis diagram) to the
Neutral terminal on the Aux Panel (please refer to item "2" on the
Aux panel diagram).
Ensure you measure the additional 10mm (approx) of wire. Once cut put a side with the
other wires.

 

You now need to repeat this process one more time with the Earth (green or green/yellow)
wire to get it's length. This wire runs from the Earth output pin on the back of the Power
chassis (refer to Item 5 on the Power chassis diagram) to terminal 7 (Earth AC input terminal)
on the power supply (please refer to item 7 in the
Power Supply diagram). Ensure you
measure the additional 10mm (approx) of wire. Once cut put a side with the other wires.

With the remaining Earth (green or green/yellow) wire run a second length from the Earth
output pin on the back of the Power chassis (refer to Item 5 on the Power chassis diagram)
to the Earth terminal on the Aux Panel (please refer to item "3" on the
Aux panel diagram).
Ensure you measure the additional 10mm (approx) of wire. Once cut put a side with the
other wires.

 

 

There should now be 6 wires of differing lengths, 2 of each colour (Live, Neutral, and Earth)
Lay them out next to each other, sorted by colour and level at one end.

 

Strip each wire back approximately 10mm to expose their cores. Give each of the
striped wires a small twist to bind all of the loose strands together. check the wires
to make sure there are no strands that might touch any other wire. If any are identified,
give the wire another twist.

 

Join the Neutral (blue) and wires together at one end and the join the Earth (Green) wires
together at one end. The Live wires (brown) are to remain separate.



 


Slip a 4.8mm spade connector cover (not pictured) over the joined end of the Neutral and
Earth wires and to one end of both the Live wires. Solder a a 4.8mm spade terminal to the ends
(terminals can be crimped, soldering will provide a stronger connection) to the ends you just
place the covers on. Once the spade terminals are attached pull the rubber covers
over them.

 

Now slip the 6.3mm Spade terminal covers over the ends of the wires that will lead to
the Aux power panel. Solder a 6.3mm spade terminal to the ends (terminals can be crimped,
soldering will provide a stronger connection) to the ends you just place the covers on.
Once the spade terminals are attached pull the rubber covers over them.

 

Attach fork terminals to the remaining ends which should be the ends that connect to the
Power supply.

 

With a Philip's head screwdriver loosen off the terminal screws labeled with the ground
symbol, "N" and "L" (terminals 7, 8 and 9). Insert the green wire (Earth) to the earth
terminal (terminal 7), the blue wire (Neutral) to the "N" terminal (terminal 8), and,
the brown wire (Live) to the live terminal (terminal 9). Tighten all screws.

 

Check to make sure the wire form the chassis Live out to the switch live in has not been
dislodged during the fit-out.

 

Attach the connected Live (brown) wire from the power supply to output pin 1 on the
power switch

 

Now run the second "Live" wire from the second output pin on the Power switch
(4.8mm end) to the "Live" input terminal on the Aux power panel (6.3mm end).
Terminals will be tight and will require some wriggling to get them on. Support
the chassis or panel from the other side while you press them on.

 

Attach the Neutral (blue) wire by first attaching the 4.8mm spade connector to the
"Neutral" output pin on the back of the Power Chassis. Then run the other end with
the 6.3mm spade connector along the desired path to the "Neutral" input pin on the
back of the Aux power panel.

 

Now to attach the final wires, the Earth (green or green/yellow) by first attaching
the 4.8mm spade connector to the "Earth" output pin on the back of the Power
Chassis. Then run the other end with the 6.3mm spade connector along the desired
path to the "Earth" input pin on the back of the Aux power panel.

 

Check all wiring to make sure none of the terminals have been bent towards each
other or are touching. Ensure all wires have not slipped out of their crimped
connectors and that all spade connectors have their rubber covers pulled over them.

 

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 power supply is now connected and ready for it's initial test while not under any
load. Once again, make sure the voltage selector is set to 240v. 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 power LED should now be
glowing green indicating everything is fine. 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

Actual picture to show Power LED

 

 

Next Step

You are now ready to move onto the next step:

Wiring the DC-DC Converter to the power supply.

 

 

 

 

Home

This site was last updated 10/20/14