Need assistance with electric enclosure please (CSMIO/AC Contactor issue)

[Clive S]

You have diagnosed this yourself the contactor will get hot if you run the coil on DC as it is has an AC coil in it. The DC coil will have a higher resistance. So you will have to change it.

Looking good though. Not sure you need two 24V power supplies.

It would be nice to have different colour cables for the DC side of things than the 240V AC stuff.

[JAZZCNC]

Simple Change the Contactor to DC type.

Looking good though. Not sure you need two 24V power supplies.

Clive the way the Cslabs units works to keep complete isolation the manual advises using separate power supply for I/O. SO that's probably why.?

[Clive S]

Simple Change the Contactor to DC type.




Clive the way the Cslabs units works to keep complete isolation the manual advises using separate power supply for I/O. SO that's probably why.?

Ok Dean thanks as they say RTFM

[Noplace]

Thank you kindly Clive, and Jazz for confirming I'm not an idiot for that setup lol

next issue is connection of safety relay and CSMIO e-stop and HV enable. to anyone familiar with the CSMIO maybe they shed a light on this, I would highly prefer to use the HV_Enable option to start up the contactor and power on the machine. I do this at the moment and is working nicely (aside from contactor issue above) but doing it like this at the moment:

HV Enable -> Safety Relay -> Contactor

safety relay is configured with E-Stop and in the future also with reset button

this works fine but I would also like to have input to the CSMIO that E-Stop was pressed (or generally safety relay disconnected) but with my current setup I can't do that because the HV enable depends on E-Stop input so it's like a racing condition and within milliseconds HV enable turns on and off immediatly due to E-Stop input not up in time ( and never would be of course ) . I feel stupid for trying this.

so is there a possible solution to have both HV_enable and E-stop, controlled by same physical E-Stop button? should I just remove safety relay from HV enable and rely on CSMIO to control the power output of the Spindle and motors? my thought process was in case CSMIO fails to detect E-Stop atleast I have a direct control of power to the main parts of the machine, is this unnecessary?

also note I prefer to use HV enable and will work around that being enabled instead of turning it off.

thanks!

[JAZZCNC]

Ok well you can only have one or the other control the Contactor other wise you defeat the point of HVEnable. The point of HV is speed so no point having the Safety relay tell Controller E-stop happened then HV shut down contactor because it's actually longer.

So the Answer is you control Both directly with E-stop using two contacts on the E-stop.
One Contact controls the Master safety Relay which you then use for System Reset and any other things you want to Kill power to like, Vacuum, Coolant etc etc.
Then have the other contact control the E-stop INPUT which then Controls HV OUTPUT and Contactor which turns on Main Drives PSU.

This way you still have Safety Relay in charge of Reset system but with the faster HV in charge of the Drives power. The HV will only turn them ON when Mach is Reset. The system Reset will only turn on Safety Relay when E-stop is clear so the System will re-set and at same time E-stop Input on controller is clear so HV is safe to turn On when Mach is Reset.

Hope this makes sense.!!

Edit: If you want double safety run the HV Output wire thru the Safety relay Contact before going to Contactor. This way if Safety relay fails the PSU will lose power.

[Noplace]

Well I won't lie I had to read this 5 times hehehe and still not sure I understand 100% but I got the main idea of two contacts coming out of the E-stop and where you're going.

let me get the chance to try it out and I'll probably post a photo of the setup to verify

as always thanks for sharing your wealth of knowledge Mr. Dean!

[Clive S]

as always thanks for sharing your wealth of knowledge Mr. Dean!

You mean Mr. Bean

[cropwell]

Looking good though. Not sure you need two 24V power supplies.

The CSLabs documentation says "If you use in the system such inductive loads as electromagnets, solenoids, electromagnetic clutches – it is recommended to use separate 24V power supply for the mentioned receivers and separate for CSMIO / IP-S."

This to me suggests that you only need one power supply if you are just switching small loads, such as relays, and a decent size capacitor across the power inputs would remove any ripple, which might cause problems.

I do not intend to go the extra expense of a second power supply unless absolutely needed.

Cheers,

Rob