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IndustryArena Forum > CNC Electronics > Gecko Drives > G540 Panel Build.. To Fuse or Not to Fuse
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  1. #1
    Join Date
    Mar 2015
    Posts
    12

    G540 Panel Build.. To Fuse or Not to Fuse

    I am building an industrial style panel for myG540.
    Gecko lays out the DC side of the wiring pretty well in their manual.
    The mains side is completely neglected.
    I understand there are way too many variables for them to even considder trying to address this.

    My question is should I fuse the PSU's on the Mains side (AC)?

    I have 3 PSU's:
    1) 48Vdc 7.3A generic from Keling for the steppers.
    2) 24Vdc 2.1A Omron for the prox switches (home switches)
    3) 5Vdc 5A MeanWell for the Crydom dual SSR control and a future Warp 9 ESS and Super PID

    I'm wiring the panel very closely to Gecko's sample wiring diagram.
    The changes are:
    1) NPN NC 12mm prox switches instead of mechanical switches
    2) Crydom dual SSR instead of mechanical relays
    3) no VFD drive, however the panel is going to be pre-wired for a super PID in the future
    4) 120mm 120Vac Cabinet exhaust fan wired into the mains after the Mains disconnect switch.

    My cabinets a bit small (12" wide x 15" tall x 10" deep)
    Real estate in there is at a premium.
    I don't want to add more DIN rail for fuse holders if I shouldnt have them.

    Thanks

    Ray in Toledo

  2. #2
    Join Date
    May 2016
    Posts
    2

    Re: G540 Panel Build.. To Fuse or Not to Fuse

    I make a habit out of fusing every branch of the mains within my cabinets. My latest has two transformers with 30V 10A secondaries, and a 24V switched supply. All three legs are fused, limiting the possible damage to the transformers and power supply if there's a problem in the circuitry that follows them.

    Need a cheap cabinet? Consider used computer cases.

  3. #3
    Join Date
    Mar 2015
    Posts
    12

    Re: G540 Panel Build.. To Fuse or Not to Fuse

    Thanks for your reply, right or wrong, it's comforting to know someone else has the same opinion.

    Funny I got this reply today, I just finished the mockup of my control panel and I did fuse all the mains.

    I have fused each PSU and each auxillary outlet.

    I have a spot on the door for a Warp9 ESS (soon)

    I need to make 1 more hole when I decide how I want to do the probe socket, I'm thinking a switchcraft XLR.

    The panel then needs a scrub and paint.

    I'm pretty sure at this point I'm going to just use spiral wire loom to keep the spaghetti neat.

    The top of the box has a panel that's missing, I think i will just put a piece of space metal screen over it with a filter sandwiched inbetween there.

    The fan runs off the 48V PSU and is rated at 100CFM @ .3A

    Most of the stuff has been salvaged from discarded/obsolete equipment from work.

    Purchased parts were the 5v and 48V PSU's, the fan and the G540.

    The pilot lamps on the front are green for mains on, The white one in the middle has a red lamp and is E Stop activated, Ill pick up the correct lens some other time, the blue lamp is manual/enabled and is controlled by the selector switch below it.

    All the lamps are PTT (push to test)

    It's pretty crowded in there, I hope I can keep the wiring neat.

    Thanks again for your reply,

    Ray in Toledo

  4. #4
    Join Date
    May 2016
    Posts
    2

    Re: G540 Panel Build.. To Fuse or Not to Fuse

    It's a good idea to draw up schematics and wiring diagrams for your interface. It's also a good idea to gather all the manufacturer's literature on everything that you used for your build. Burn it onto a DVD. Manufacturers and retailers are here today, gone tomorrow. Here's the drawing I did for my power supplies:
    Click image for larger version. 

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  5. #5
    Join Date
    Feb 2007
    Posts
    962

    Re: G540 Panel Build.. To Fuse or Not to Fuse

    If you are ever planning on selling the machine, it needs to be safe and not cause a fire.

    It doesn't matter what burns up inside the cabinet.. its the external wiring that inspections care about. If you use #24 wire in your harness for limit switches, the BOB needs to be fused to not exceed the current of #24 wire. They assume if chips fail on the BOB, full PS current could flow. ( although highly unlikely)

    Every stepper drive should be fused so if a drive fails it doesn't smoke the motor or wiring to it.
    .
    Early IBM PC'c power supplys didn't have fuses for mouse and KB.. when people would pinch the KB cable in a office drawer, the PC powersupply could output 25 amps and cause a fire.

    Larry
    Manufacturer of CNC routers and Viper Servo Drives
    www.LarkenCNC.com and www.Viperservo.com

  6. #6
    Join Date
    Feb 2007
    Posts
    962

    Re: G540 Panel Build.. To Fuse or Not to Fuse

    Don't put switches or breakers after the transformer . That is hard on drives.
    Manufacturer of CNC routers and Viper Servo Drives
    www.LarkenCNC.com and www.Viperservo.com

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