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Hi Paulro Clive brough this to my attention did you get this sorted.? . . . If not what's your fear with releasing magic smoke.?

The way I read the manual the inputs will take up to 30V there is a 1k Resistor in circuit that will limit the current at 24V to 24mA so not a dead short. Dean will no doubt pop along and give you...

Are you controlling the vfd via mach3 or are you changing the speed by the panel on the vfd if so I did a post here http://www.mycncuk.com/threads/7388-Fitting-a-pot-to-a-Chinese-Spindle-VFD post 1...

If you have one just for testing sake then try a 10amp Mcb it may work for you to get going and check all the sytem correctly.
Don't cut corners with the electrical safety or hot wiring system just...

I need a re-cap on what your using for the main PSU.! . . . Safety relay won't do anything for inrush current if your using toroidal PSU.
If PSU is toroidal then try a D rated MCB.!! . . . . But...

Depending how big your transformer is you might have to rate the mcb a little higher see this: http://www.neweysonline.co.uk/MCBs/Static.raction ..Clive

1600 MS is fine.

Several ways to use the Fault signal but an easy and safe way is use a Relay with the coils wired in parallel running thru fault signals set Active low and the E-stop running thru...

Paulro
I have used just cat5 twisted pair to each drive cable for the step/dir etc just keep them away from the motor cy cables.

Not necessary to screen them

Will be fine without shield to earth for short runs just try to keep any signal wires away from higher voltage wires like Mains.

Ok well think things could all change now if you wanted because I'm pretty sure that Bob can handle 24v thru it's inputs.? The manual certainly shows them using 12V.

So in this case you could...

Probably not but Depends on the BOB.! . . . what are you using.?
It's common for the Enable on drives to not be connected but in this case we are using it to ensure no signals get to the drives so...

The way I do it is to use a Relay for limits. This means I can use 24V thru the switches to power the relay coil, in my case Proximity switches, which gives best immunity against noise.
The drive...

Sorry delay replying went out last night for a pint which turned into Gallon then Amnesia.!! . . Well No and yes to getting it wrong.?
Mach as feature called Auto Limit Override which lets you...

If your going to have a feed hold button then you need a Cycle start button to get going again so you'll need an input for that. No point having External feed hold button without cycle Start.!
...

Ok
1: = yes
2: = yes
3: = yes
4: = yes
5: = yes
You can add an extra two BOB's to your motion controller if you like then you would have 15 inputs. ..Clive

Its good practise to put fuses in the +ve side and the mcb for the input to the transformer appears to be 3A I would think you need more like 6A because of the inrush to the coil and rate it to a...

Can I make a few suggestions.!!

I wouldn't locate the VFD and the PSU next to the BOB and Motion control card and drives. Both these are very noisey devices and they could introduce noise onto the...

Ok well here goes lets hope this sheds some light.!!

Starting with motors and series or parallel wiring.?
This is a choice based on how you arrange the 8 wires. In your case for parallel wiring...

Depends really where you stand at the machine. Often routers are viewed from the side in which case viewing from the front it would be back left corner and long axis woul'd be X axis. Viewing from...

This going to sound obvious when I say it.!! . . . . Where ever you want HOME to be.!!

Generally you'll position them so they follow Cartasian coordinates ie Bottom left corner and in front of the...

What drives are you using.? If 80V max then it will be fine but if 75V max then it's a little close for comfort because as Clive says mains does fluctuate. When your reading 73Vdc what is the Mains...

Its fine at that and are measuring it without a load as well also the mains voltage will fluctuate.
How about a pic. ..Clive

You could use cat5 flexi cable or a screened cable for all the switches and limits, Estop etc. 1.5mm CY 4 core for the steppers (don't forget to ground to a star point at the driver end) and a bit...

Ok short black and yellow together and take the output from red and orange then you should see 50V You have connected them in parallel . I think the fuse is blowing because of the surge. ..Clive

Do you have a link for the coil?

You need to connect the two sec. coils in series so join red and yellow and measure black and orange 50V It might well blow the fuse on start up with a 625w coil...