Avoid Release of Magic Smoke - Read the Documentation

While awaiting the delivery of the CNC Router kit one of the best uses of my time is to get the CNC Controller setup, configured and tested. When working with any type of electronic device it is important to avoid releasing any of the magic smoke hidden within. When the magic smoke is allowed to escape from an electrical component it usually ceases to work, clear evidence of the importance of the magic smoke to its proper functioning.


One of the best ways to avoid the inadvertent release of magic smoke is to make sure everything is connected correctly before applying power. To this end I will carefully review the following documents:

• Power Supply Spec Sheet
• Stepper Motor Spec Sheet
• Gecko G540 Manual
• Gecko G540 Initial Setup Guide

Electrical Components Arrive

Arriving home from work today I was pleased to find my CNC Router Parts order had arrived. As mentioned previously this past Sunday I placed an order for the stepper motors, power supply, cables and Gecko G540. Ahren at CRP apparently got the order out right away and made the necessary arrangements for a prompt delivery by a uniformed agent of the Federal government.

No excuse now for not making some progress this weekend.

CNC System Diagram

Updated 10/26/2009

This post will be a sticky post since I expect this diagram to change as I learn more about what I am doing.

CAD/CAM Workstation

I will be using an existing PC to create 2D and 3D geometry using CAD and other applications. This system will also host any CAM applications used to program tool paths and to generate the G-Code files. The resulting files will be transfered to the CNC Controller by sneaker-net or using our wireless network.

CNC Controller

I am most uncertain about this portion of the system. As best I can tell the "CNC Controller" will consist of a PC running CNC Controller software, such as Mach 3, and a hardware controller box that has a Power Supply, a break-out-board and stepper motor drivers. I have more to learn about the function of the break out board but it includes isolating the PC from the high current and voltage being sent from the drivers to the stepper motors.

The Controller PC and Controller Box are connected through a parallel interface. I am planning to dredge out a decommissioned mother board and CPU from the closet and build up a PC dedicated to this CNC Controller function. I have a spare NEC LCD monitor for this system. These will live in the garage/shop with the controller box and router.

Stepper Motors

The stepper motors are connected by cables to the controller box drivers. Depending on the router design there will be either 3 or 4 stepper motors. The Y axis can be driven by dual motors or a single motor.

Machine Tool

The stepper motors are attached to the machine tool and its lead screws. The rotation of the lead screws move the gantry and carriages which hold the router spindle along their axis.