The MASSO has a relay driver that will activate a relay when in an Estop state.

Previously I had used this relay to Enable/Disable the G540 with an Estop switch was wired to the MASSO all was good.

 

The Problem

The G540 is a pretty smart driver. It will generate a fault error on power problems, overheating problems, and on its own Estop.  This is a good thing but I needed to get the faults back to the MASSO so it would stop a running job if a fault is triggered.

The first issue came from the fact that fault pin on the G540 DB25 could not drive any of the inputs on the MASSO.  No problem, I purchased and wired up a small relay board. I got the G540 to fire the relay when a fault occurred, and I used the relay to drive one of the inputs on the MASSO.  I configured the MASSO to treat the fault as a "X Motor Error" and this would cause the MASSO to raise an alarm.

The second issue came from the raised alarm.  Most alarms triggered by the MASSO require you to do a homing sequence to clear.  But this assumes you have done all your homing switch upgrades.  With no homing switches you cant clear the alarm without cycling power.

Please note that even hitting the Estop button will cause a fault that requires you to home the machine.  This even includes the initial Estop cycle that is required once the MASSO has booted.

The Work Around

 Instead of using the MASSO to drive the G540 in an estop state, I used the G540 to drive the MASSO, much like it drives a PC and Mach3. 

 

The Relay Board

I started with this small two channel 5V relay board.

I did add the green screw terminals, as it came with a 4 pin header.

The first thing I did was to mount two of my short DIN rail brackets.

I then attached the relay board with two small #4 machine screws.

 

Connecting To the G540

In order to connect the MASSO to the G540, you will need a DB25 breakout board.

While we will be connecting more wires later, for now all you need are two 24" long pieces of wire. I used a blue and yellow wire.

I connected the blue wire the pin 25 which is G540 ground. I connected the yellow wire to pin 15 which is G540 fault output.

I then plugged the connector into the G540.  Notice the amount of excess wire that I have on the connector.  This so I have room to remove the connector as needed for aditional wiring.

 

Wiring the Relay Board

Relay Board Input

The yellow wire (pin 15) from the G540 was connected to the relay board input #2.

The blue wire (GND)  from the G540 was wired to the ground terminal blocks.

I then wired the GND connector (black wire) on the relay board to the ground terminal blocks.

I wired the VCC connector (red wire) on the relay board to the 5V terminal blocks.

Relay Board Output

The relay contacts are wired to the blue screw terminals on the relay board.

I wired the center contact for relay #2 on the relay board (red wire) to the V12 terminal blocks (MASSO VCC).

I wired the NO contact for relay #2 on the relay board (yellow wire) to the MASSO Estop pin 2.

Note that this relay board fires on a low signal. So in a no fault condition the relay is active.  This is why I used the normally open contacts.  Other relay board may work the opposite, so you would use the NC contacts.

 

Wiring the Estop Switch

Two wires are connected to the NC contacts on a mushroom style switch.

One wire is connected to pin 10 on the screw terminals of the G540.  The other wire is connected to the ground termanial blocks.

 

When ever the G540 is in Estop or fault state the MASSO sees it as an Estop.  You use the G540 Estop just like you would the MASSO Estop.  After cycling power on the MASSO, you must always cycle the Estop to clear the initial Estop state.

 

If you have the upgrade workbook and want to hookup additional Estops that are mounted on the machine.

Keep in mind that they are connected in series with the existing Estop shown here.

Remove the ground wire on the switch and connect one side of your machine mounted Estop switches to the switch terminal and the other to the ground terminals.

Or you can remove the switch on the proto board all-together and just connected your machine mounted Estops in its place.

If you have the upgrade workbook and want to hookup aditional Estops that are mounted on the machine.  Just keep in mind that they are connected in series with the existing Estop shown here.  Remove the ground wire on the switch and connect one side of your Estop switches to the ground wire and the other to the switch terminal that you removed it from.

 

Some Additional Links

 

MASSO Estop Connections

Emergency Stop Switch