Thanks for the help so far.

I'm not sure if this post is to try and validate my assumptions or a cry for help?


I've gathered a lot of info on here and elsewhere and frankly, my head is spinning wrt to the controll box, wood or metal aside. I understand how to connect my drivers and VFD to my controller and I have confirmed my understanding by testing it without blowing anything up but if I look at the great control box projects and circuits on here, there's apparently a hell of lot more to it than that e.g. safety circuits and all sorts of contactors, relays etc. which has me questioning my plan. I'm trying to figure out whats really the bare essentials. I am guilty of some serious OTT stuff but when it comes to the electrics/electronics I just don't have the experience or knowledge to pull off anything elaborate.


My requirements are simple and I'm trying to achieve it in the simplest way possible. Please correct me if I'm missing essential safety requirements


1) I need an Estop that will let mach3 know its pressed and to disable my drivers but will leave the spindle running. My estop switch has a separate NC and a NO circuit so when pressed I'm thinking to use the normally open circuit to send a signal to mach3 and the NC circuit to disable my drivers.
No relays or anything fancy, just 1 x 5V circuit to my controller to let mach3 know and one 5V circuit running thru my 4 drivers enable pins in serial. With this approach I understand if I click estop in Mach3 it will stop sending instructions to my controller but it will not disable my drivers which is fine with me.


2) I'll operate my VFD manually wrt to run and stop and only use my controllers 0-10V output to change speed. Nothing else, no relays etc

3) Don't really have a plan what to do with the fault signals from my drivers? I need to disable all drivers if any one faults but not sure how to accomplish this in the most basic fashion? Maybe that's the stuff I see in other control boxes that I don't have the foggiest clue about :-)

4) Limits and Home switches. I actaully considered not fitting any as I've never run my old machine into the limits but my build is a lot smaller than that so its probably a bad idea. I'm thinking of fitting limit switches for Xmix,Xmax,Ymin,YMax and Zmax with one NC circuit running thru all the switches in serial. I'm not too concerned about homing as my controller do not have the capability for dual x axis home anyway and on my old machine I always cut from a G54,55... offset and I can't foresee me using the new one any differently. I'll configure mach3 to use the limit switches for homing for whatever its worth.


5) My control panel will consist of only the EStop switch and a 220v 24Amp circuit breaker that will cut all power to the machine (controller, drivers, vfd and waterpump) Guess which one I'll be going for when the sh%t really hits the fan :-)


6) My waterpump will run all the time when the main circuit breaker is on. In time I'll figure out how to use the build in relay in my VFD and use that to switch the waterpump on and off.


7) Apart from proper grounding of all the 220V stuff I have no additional safety anything, no contactors, no filters, no relays, no nothing.


Is this a realistic workable plan as a first stab at my control box or am being ignorant?


Sorry for the long winded post!