4' x 4' x 8" Router Build

[JonnyFive]

@Neale those drives are software configurable.
I'm not entirely sure why they bother with microswitches for some settings, given other critical settings have to be set in software.

@JonnyFive if you need the software, I've got the install file for V2.1.8, which lists your drives.

So there’s an app I need to configure the drivers? I did not know that. Presumably they are set to 6A from the factory, am I likely to need to change it?

[m_c]

Just to clarify something on the current requirements, a 5A stepper motor won't draw 5A from the power supply, except in very specific circumstances which are not actually likely to occur.

Say a stepper is rated 5A at 10V while stationary (nice round figures for simplicity, but voltage is likely to be 3-5V for most common steppers), that means at idle, it will consumer 50W (5V x 10A).
If you power that via a 50V transformer, that means at idle the drive is only going to pull 1A (50W/50V). (assuming 100% efficiency - typical efficiencies are going to be in the 90s)

However, once the motor starts spinning, the motor requires more voltage to maintain the rated current due to the generated back emf, so at some point the drive will reach a point where there is not enough voltage for it to maintain the full 5A current, and this is the point where maximum power supply draw will be pulled. As you move above that point, which I'll call the peak power point, current draw will actually decrease.
However (yes another however!), stepper motors are not that efficient, so in practise the current actually drops of before reaching the peak power point, due to that pesky inductance which limits how fast the current can be changed in the coils.

[JonnyFive]

Just read the manual for the driver, looks like you need to connect via the comm port to tweak the current. I ain’t gonna do that The manual says the current will be adjusted automatically.

[JonnyFive]

Let’s talk fuses, how does one work out what amperage to use? Just add up all the current draws within the circuit? Add a bit on top for luck?

[JonnyFive]

I've been researching wire sizing for my build and here's what I've come up with:

1) Cable from wall socket to cabinet - 3 core, 2.5mm² flex
2) 240Vac within cabinet - 2.5mm²
3) Earthing - 1.5mm²
4) 24Vdc signals - 0.5mm²
5) Proximity switches - 3 core 0.5mm² CY
6) VFD to spindle - 4 core 1.5mm² CY
7) 55Vac within cabinet - 2.5mm²
8) A+ / A- / B+ / B- - 4 core 1.5mm² CY
9) EGND / VCC+ / EA+ / EA- / EB+ / EA- - 1mm² CY
10) PUl+ / DIR+ - 0.5mm² twisted

How does that all sound?