Electronics set for a small plotter V1

Cheaper in a set!!!

The presented set is a response to our customers' great interest in components for building the control of their first CNC machine. The purpose of completing the set was to facilitate the selection of electronic components when creating controls for hobby and industrial machines. Based on our many years of experience, we offer you the most reliable components that have enjoyed unflagging popularity for many years. Thanks to these elements, anyone with a bit of electrical engineering knowledge is able to build a professional numerical control system. The elements have been designed so that the control can be assembled like "Lego blocks". Just make connections that have been limited to the minimum necessary.

Please read the description of the proposed set below. If you have any questions or comments, feel free to call or write to us. Our specialists are at your disposal.

List of elements:

• SSK-B03bis stepper motor drivers – 3 pcs
• SSK-MB2 CNC control motherboard – 1 pc
• MZ-01 power supply module – 1 pc
• Transformer TR 420 230/ 2 x 30V – 1 pc
• SOFT START soft start module – 1 pc . Only now for free!!!
• FM-02 fuse module – 1 pc
• FM-01 fuse module – 1 pc

The kit allows you to build a CNC machine control. These may include plotters, milling machines or laser burners. Depending on the engines used, the machine will be able to process aluminum, plastics and wood.

Why is it worth buying an electronics set for a small plotter?

• You can adjust the set to your needs in terms of the number of axles;
• The set will allow you to freely configure the motors for each axle;
• The price of the set includes a free Softstarter system
• When purchasing stepper motors (selected models) together with the set in question, you will receive an additional discount on their purchase
• The presented set has a very good value for money and features;
• Dozens, if not dozens, of similar sets are already in operation in Poland and abroad;
• You can very easily adapt the control to operate various types of numerically controlled machines. You can, for example, build a machine that has a plasma torch, a laser head and an electrospindle installed at the same time, and use these tools alternately during operation. You can also control a plasma burner, a milling machine, cutting plotters, styroplotters and all kinds of devices based on numerical control in the Cartesian system (XYZ). Thanks to expansion modules prepared for the SSK-MB2 motherboard, the control system can be expanded with new possibilities. For example, using the SpindleControl module, you can control the rotational speed of the electrospindle via an inverter. Using the Kanthall module, it will be possible to regulate the temperature of the wire in Styrofoam units. After using the THC torch height adjuster, you can automatically adjust the torch height in your plasma cutter;
• By building your own controller and going through all configuration stages, you will gain knowledge and skills that will allow you to fully use the machine's capabilities. Additionally, the experience gained will facilitate the diagnosis and repair of any faults that may occur during operation of the device.

The selected motherboard and power supply system enable the connection of up to 4 SSK-B03 bis controllers. Thanks to this, in the future you will be able to expand the control, e.g. with a fourth axis - a rotary one, or use the slave axis function, which will enable, for example, the simultaneous drive of the gate of the device being built with two motors.

You should choose stepper motors for your set. Our offer includes a wide range of stepper motors - from the smallest Nema17 ones used in the construction of 3D printers, to Nema43 motors with a holding torque of up to 50Nm - used in the largest milling machines or robotic arms. The choice of engines will be dictated by the need for the control system being built, depending on the demand for power and speed of the engines. Below is a list of motors, which for the purposes of the presented set is limited only to motors matched in current to the proposed controllers:

• Stepper motor FL57STH56-1006A - 0.9Nm
• Stepper motor SM 42/33-1334B – 0.22Nm
• Stepper motor SM 42/38-1684B – 0.36Nm
• Stepper motor FL57ST41-1564A - 0.39Nm
• Stepper motor SM 42/47-1684MB – 0.44Nm
• Stepper motor SM 42/47-1684B – 0.44Nm
• Stepper motor FL57STH56-2804A – 1.2Nm
• Stepper motor SM 57/56-3008B - 1.2Nm
• Stepper motor SM 57/76-3008B - 1.9Nm
• Stepper motor FL57STH76-3006A - 1.35Nm
• Stepper motor FL57STH76-2804A - 1.89Nm
• Stepper motor FL57STH76-2804B - 1.89Nm
• Stepper motor SM 57/76-2008B - 2.0Nm
• Stepper motor FL86ST94-4008A – 3Nm (series connection!!)
• Stepper motor SM 60/86-3008B - 3.1Nm

I would like to remind you about the promotion for stepper motors when purchasing them together with the discussed set of control elements. The discount will be applied automatically after adding items to the cart.

The SSK-B03 bis power output stages used in the system are characterized by high efficiency and accuracy. The ability to reduce the stand-by current of the motor coil to 50% of its value prevents the motors from heating up, which translates into the durability of the entire system (our controllers and motors are in use and have been working together without failure for 10 years!).

The SSK-B03 bis controller is an economical, failure-free, high-performance microstepping controller. It is adapted to control 2-phase and 4-phase stepper motors. Using advanced control techniques, it allows you to obtain greater speed and power from the same engine compared to traditional control techniques. Its advanced control technology allows for correct control of the coil current while maintaining low ripples, which in turn results in reduced motor heating and improves operating smoothness. All this translates into high quality processing. Thanks to this, you will be able to complete the detail with greater accuracy in less time.

This controller can be used in many different machines, such as: XY positioning modules, labeling machines, laser cutting, cutting plotters, plasma cutting machines, lathes, engraving machines and pick-up and carry devices.

It is particularly useful in applications where high speeds and precision (positioning systems) are required while maintaining high work culture (quiet and uniform operation). A wide range of supply voltages 20-50 VDC makes it universal in use and allows adaptation to various ready-made control systems.

Motors and their controllers require power. The set in question uses a linear power supply system, which consists of a TR420 toroidal transformer with a rated power of 420 Watts and an output voltage of 30VAC and the MZ-01 power supply module. Our experience shows that this is the best power supply solution for stepper motors. Only now, when purchasing the set, you will receive a Soft-Start soft start module as a gift, which is necessary for the operation of a transformer with such power.

The SoftStart system, i.e. the soft start module, limits the value of the current pulse that is generated in the transformer windings when it is connected to the network. In practice, this phenomenon is important when the transformer power is greater than 200W. When connecting a system with a transformer to which a rectifier bridge and large capacity capacitors are connected to the network, the starting current consumed by the system has much higher values than the rated currents (depending on the power, it can be up to 10 times higher). High values of starting currents trigger the protection, which disconnects the power supply to the entire system. This is particularly troublesome when a computer and a machine controller are connected to one power strip. If the fuse trips, the computer will turn off, causing the loss of unsaved data. By using the SoftStart module, we eliminate this situation and we can work on the computer and the machine controller without any worries when they are powered, for example, from one power strip (common fuse).

The MZ-01 power module is used to power electronic devices that require high-power, unstabilized voltage. It has two power supply paths: a non-stabilized one for powering stepper motor drivers and a separate stabilized path for powering logic - we have two voltages available: 5 and 12VDC, with a total current capacity of 1A, which will be used to power the SSK-MB2 motherboard circuits. The module signals the presence of each voltage with LED diodes.

The next elements of the set are two fuse modules FM-01 and FM-02. The FM-01 module makes it easier for us to connect stepper motor drivers from individual axes of our machine to the power supply system discussed above. It has built-in fuses to protect individual output stages and the motors themselves in the event of a short circuit. Let's imagine a situation where the motor is connected to the controller with a cable placed in a guide; the coatings of individual wires of this cable may be kinked or abraded, leading to a short circuit, which may damage the controller. In such a case, the FM-01 module will limit the effects of such a failure only to blowing the fuse. Otherwise, the controller may also be damaged. The presence of voltage in individual axes is indicated by an LED, which makes it easier to assess the situation in the event of a failure.

The FM-02 module has an identical purpose, i.e. power distribution and protection, except that it is mounted at the input. We install it on the power supply side of the machine controller. It can also be used in any device to connect a switch, power indicator, fan, or an additional receiver via an independent fuse. Both channels of the FM-02 module are protected by two protections - current and overvoltage.

Both modules eliminate additional connectors and tangled wires, improving the clarity of the system. This is particularly useful in the event of a device failure. The compact solution also ensures the aesthetic appearance of the device.

The last element of the set is the SSK-MB2 motherboard, which was designed to facilitate the connection of up to 4 stepper motor drivers (or servo drives) to a PC equipped with an LPT parallel port. It divides individual signals from the port pins into ARK screw connectors, which will significantly facilitate and shorten the time of assembling the control. Thanks to the built-in opto-isolation circuit, it is possible to easily adjust the voltages when connecting peripherals such as: limit switches, emergency stop button or machine control buttons such as "START", "STOP", etc. We have 5 inputs at our disposal. The board has two built-in relays with high switching current. You can use these relays to switch on various devices while the machine is running, e.g. you can start the spindle by sending a signal to the inverter; you can also start the coolant pump, or chip extraction, etc. These are the most common applications, but in fact your possibilities are endless. If the device you want to start has a higher power, you should use an intermediary contactor to increase the switching power. Because the relay should only be used to switch on the circuit and not to transmit operating currents.

It is also worth mentioning the possibility of increasing the number of relays. This will be possible if we do not use all 4 axes in the machine. Then, by adding the PPK-01 relay board, we can expand the system with additional 4 relays. We will then need 4 outputs from the motherboard. Details in the instructions for the motherboard and the PPK-01 relay board. Detailed information about the motherboard configuration can be found in its user manual.

It is possible to expand the control with a larger number of inputs and outputs. In such a case, please contact us and we will help you select the appropriate components.

ATTENTION!!! Before assembling the kit, and then when starting the device for the first time, remember that each machine is potentially dangerous. The system contains a voltage of 230VAC that is dangerous to health and life! Numerically controlled machine tools may pose a greater risk than manual ones. Self-moving system components expose the operator to danger. Avoid contact with them and keep a safe distance when the power supply is on. The system integrator is responsible for the final application. He should ensure that the machine is constructed in accordance with applicable standards and legal regulations. Modules intended for installation can only be used and operated when placed in an appropriate cover. In places where an error in the automation system may result in injury to persons, damage to equipment or high financial losses, additional precautions must be taken. They will ensure safe operation of the machine tool in the event of damage or disruption (e.g. independent limit switches, mechanical interlocks, etc.). The manufacturer and distributors are not responsible for financial losses or injuries resulting from improper use of the device and not as intended.

Depending on the outcome of the risk assessment for the entire device, it may be necessary to implement additional safety measures to be incorporated into the system.

Due to the presence of dangerous voltages in the system, all connections and any changes in the system must be made with the power supply switched off!!! Safety first. If you do not feel up to it, all connection work should be entrusted to a person with appropriate authorizations and skills.

Before starting the connection work, please read the instructions for the set and the instructions for the individual components of the system in detail! When installing, follow the art. We remind you of a few basic rules:

• remember to use cables of appropriate diameter so that they are adapted to the currents expected in a given circuit, taking into account the way and place of their installation; In case of significant cable lengths, when selecting their diameters, voltage drops should also be taken into account (this may prove important, e.g. when connecting motors to the controller);
• individual circuits should be protected with fuses with appropriately selected release currents;
• the arrangement of cables inside the cabinet and on the machine itself is also important - it affects the so-called electromagnetic compatibility – EMC. All connections should be made in the shortest possible lengths. If possible, separate control cables from power cables. Such wires should be at least 10 cm apart, and if they must touch, only at a right angle. Control cables, e.g. connecting the motherboard with stepper motor drivers (step, direction and work permit signals) should have a screen, the so-called the braid, which should be grounded on one side using a special clamp ensuring the largest possible contact surface; Similarly, the cables connecting stepper motors with controllers or the electrospindle with the inverter should be shielded and properly grounded;
• At the assembly stage, special attention should be paid to the correctness and quality of electrical and mechanical connections (e.g. attaching individual elements to the mounting plate). A poorly tightened screw may not provide a reliable electrical connection, which may result in the signal being lost during operation, e.g. as a result of shocks - finding such a fault may be very difficult;
• Remember to properly ground the control cabinet and the machine itself;
• According to the risk assessment for the machine, the required safety circuits must be provided in the control system;

a) Example of system power connection

b) Example of power supply connection for SSK-B03 controllers using the FM-01 module

c) power supply for the logical part of the SSK-MB2 Board

d) Connecting control signals from the SSK-MB2 board to SSK-B03 stepper motor drivers

e) Connecting stepper motors to controllers

The SSK-B03bis controller can control hybrid stepper motors with 4, 6 or 8 pins. The diagram below shows connections to motors in various configurations.

A+ - the beginning of the first motor winding

A- - end of the first motor winding

B+ - beginning of the second motor winding

B- - end of the second motor winding

NC – (No Connected) - the ends of the wires must be insulated - DO NOT CONNECT

4-wire motors are the least flexible, but the easiest to connect. The speed and torque will depend on the impedance of the turns. When setting the driver output current, multiply the unipolar current by 1.4 to determine the driver's peak output current.

6-wire motors can be connected in two configurations: the so-called full or half coil.

The half coil configuration otherwise known as higher speed is so named because it uses half the turns of the motor. This allows the impedance of the windings to be reduced, which allows the current in the windings to increase faster, allowing the motor to operate at higher speeds and accelerations. Higher speed requires higher current. When setting the driver output current, multiply the phase (or unipolar) current by 1.4 to determine the peak output current.

The full coil configuration uses the entire impedance of the phase turns. This application should be used where higher torque is required at low speeds. Since we use all windings, a smaller current is enough to obtain the rated torque. At higher current values, the motor may be damaged. Since two half coils are operating at the same time, excessive engine temperature may occur. To avoid this, we should only set the controller to 70% of the motor's rated current; therefore, to determine the RMS motor current, we multiply the motor phase current (unipolar) by 0.7. To determine the PEAK value for microstepping controllers, we multiply the obtained value by 1.4.

8-wire motors offer the greatest flexibility to the system designer because they can be connected in series or parallel, allowing for use in many applications.

Series connection is typically used where high torque and low speed are required. Since inductance is highest with this configuration, efficiency drops at higher speeds. Therefore, in order to determine the motor current (RMS), we multiply the motor phase current (unipolar) by 0.7. To determine the PEAK value for microstepping controllers, we multiply the obtained value by 1.4.

The parallel connection of the motor windings offers more stable torque at higher speeds. This method of connecting the windings allows the impedance of the windings to be reduced, which allows the current in the windings to increase faster, allowing the motor to operate at higher speeds and accelerations. Higher speed requires higher current. To determine the motor winding current in such a configuration (RMS), multiply the motor phase current (unipolar) by 1.4. To determine the peak output current of the controller (PEAK), the result should be multiplied by 1.4. Or we immediately multiply the phase current (unipolar) by 1.96 to determine the peak current (PEAK) for microstep control.

After selecting the configuration with which the engine is to operate, unnecessary (unconnected) wires should be thoroughly isolated from the rest. We can now start connecting the cables to the power stage. Particular care must be taken during this operation. Poor connections may result in incorrect operation of the motors, interference or, in worse cases, short circuits and damage. In order to reduce interference, the motors should be connected to the cabinet with shielded cables, which should be properly grounded.

Example of grounding the cable braid using a special grounding clamp.

Before starting the controller for the first time, we suggest checking the connections of controllers, motors, limit switches, relays, etc. again. The check should be carried out in terms of the correctness and quality of the connections made. Careless preparation of the wiring may result in damage to the control or its unstable operation. Once again, we check the current settings on individual stepper motor drivers. We connect the computer, run the program and turn on the controller.

In order for our system to truly 'come to life', we need to give it 'reason'. In this case, it is the Mach3 program, one of the most popular CNC machine control programs in our country, both for commercial and hobby solutions. It controls the operation of stepper motors or servo drives by sending step and direction signals (Step/Dir). This program works perfectly with all controllers available in our offer. Using the Mach3 program, we can transform the computer into a CNC machine controller. It enables, among others, the control of the following machines: plotters, milling machines, engraving machines, lathes, plasma burners and Styrofoam cutters. Thanks to the ability to emulate a PLC controller and ModBus communication using this program, we can transform a PC into a controller for virtually any machine. Moreover, our clients have successfully implemented the control of a pipe bender, an automatic welding machine or a powder coating device.

Using the Mach3 program, you can control any device that has a maximum of 6 axes plus a spindle. The Mach3 program controls their work based on the so-called G-codes that you can prepare from vector files, for example using LazyCam or MeshCam. The Mach3 program can control any set of controller and stepper motor. Any mechanical drive transmission solution (screws, strips or toothed belts) can also be used. In this program, you can define the operating parameters of each axis separately. You also have a preview of the tool path and can constantly control machining parameters, such as feed speed or spindle speed. The program is available in a demo version, the use of which will allow you to familiarize yourself with the program's capabilities, which should make it easier to decide to purchase a license. The demo version is fully functional, it is only limited to 500 lines of G-code. After purchasing the license, the program limit is 10,000,000 lines of G-code. Files are available for download on the EBMIA.PL website that will help you configure the program to work with the presented set. This file contains the settings for the pre-configured control. All you have to do is specify what inputs and outputs the peripherals are connected to and what type of drive transmission was used in the machine being built.

The programs discussed: Mach3, LazyCam and MeshCam are available in our store. The programs should be tested and then reconsider the purchase, because it is not possible to return the purchased license.

When designing and constructing the cabinet, remember about the switchgear housing and the cooling system, the selection of which should be dictated by the operating environment of the control device. You can use such a housing for this purpose. These buttons and the cam switch may also be useful.

When building a CNC machine control yourself, an article describing the construction of a control panel may be useful.

This manual has been prepared as a proposal for the independent use of elements and products available for permanent sale in our store. The entire system can be freely changed and configured to meet specific requirements and expectations.

We also offer the possibility of custom-making a control cabinet with any parameters, or purchasing a ready-made Universal Numerical Controller best suited to your requirements. All information is available on our website. If you have any questions, please contact us. We also invite you to personally visit our company's headquarters located in Augustów at ul. I-go Ułanów Krechowieckich Regiment 18. We work from Monday to Friday from 8:00 a.m. to 5:00 p.m.

We wish you successful work and fun creating control systems yourself. CNC Accessories Team.

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