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E5X Wiring Guide

1.0 Introduction

The E5X MCS T4.1 (“E5X” for short) is an Ethernet controlled 5-Axis Motion Control System powered by a 32-bit Teensy® 4.1. It is an easy-to-use and powerful motion control system that can drive up to 5-axis (+1 clone/slave) CNC machines.

The E5X is designed to run grblHAL firmware, which is fast becoming the firmware of choice for CNC control due to increased functionality and added features, far surpassing the current 8-bit CNC controllers on the standard port of grbl or grbl esp32. Connectivity is established through a native ethernet or USB port – depending on the user’s CNC requirements. 

The E5X outclasses all GRBL-based controllers and is modularly adaptive. Powered by a Teensy® 4.1, the E5X exceeds the currently available technology, with future upgradability built into the design. As advanced CNC components steadily increase in availability, a capable and adaptable controller to take advantage of these advancements is a must-have for all CNC machines. Proudly designed and tested in Australia by the team at Maker Store – a wholly owned Australian company.

The Maker Store E5X MCS T4.1 is the cutting edge of grbl powered motion control systems with upgradability built into the design. This is the future of CNC and motion control.

To know more about the features and specifications of E5X MCS T4.1, please click here

Please Note: This guide provides instructions for connecting the E5X MCS T4.1 controller specifically to Maker Store CNC machines. If this controller is used with other machines or for alternative application, users must research and find solutions that suit their unique application and requirements. 

1.1 Tools Required

Use the below-listed tools to connect the E5X to your machine. For the best wiring connections, we recommend crimping the wire ends with ferrule terminals.

  • 2mm Flat Head Screwdriver
  • Spade terminals
  • Ferrule Terminals
  • Wire Stripping tool
  • Crimping tool

Note: The above mentioned tools are not supplied with any of the E5X bundles. 

2.0 Safety and Handling Requirements

Safety Statement
The author of this document is not liable or responsible for any accidents, injuries, equipment damage, property damage, loss of money or loss of time resulting from improper use of electrical or mechanical or software products.

Assembling electrical and mechanical machine components like power supplies, motors, drivers or other electrical and mechanical components involves dealing with high voltage AC (alternating current) or DC (direct current) and other hazardous items which can be extremely dangerous and needs high attention to detail, experience, knowledge of software, electricity, electro-mechanics and mechanics.

BEFORE MAKING ANY CONNECTIONS OR DISCONNECTIONS POWER MUST BE REMOVED FROM THE DEVICE AND THE CONTROLLER. FAILURE TO DO SO WILL VOID ANY AND ALL WARRANTIES.

Before starting please read through all the instructions.

Note: Any Mains power connections must be installed by a Licensed Electrician or suitability qualified person.

ALWAYS disconnect the power before connecting or disconnecting the stepper motors.

ALWAYS connect a stepper motor to the E5X when testing or using the E5X and driver. This is essential as the stepper drivers are designed to ramp up the current until it reaches the current needed to run. Without the stepper motor connected, there will be nothing to consume the current, and it may damage the stepper driver if it over heats in the process.

All Errors and Omissions Excepted - feedback is, of course, welcome!

3.0 Wiring – The E5X to Power Supply Unit (PSU) 

The E5X has two power inputs that have the following power requirements:

  • 24V 2A
  • 5V 2A

Use the Mean Well RD-65B series 66W Dual Output power supply with an output current rating of 4A at 5VDC and 2A at 24VDC to meet the above requirements. 

E5X Manual Images (18)
Click to expand

Important
It is important that the power supply outputs are measured with a multimeter prior to connecting to the E5X. The power inputs must not exceed 24V for the 24V DC input connector and 5V for the 5V DC input connector on the E5X MCS. The onboard circuitry may be irreversibly damaged if the supply voltage exceeds the specified voltage.

To connect the Dual Output power supply to the E5X follow the below steps:

Step 1: Loosen the +V2 and COM and +V1 and COM terminals on the power supply and the 24V+ and GND and 5V+ and GND on the E5X. 

Step 2: Take 1 metre of DC Cable – 2 Core – 2mm (Red and Black Wire), use the red wire to connect the +V1 output of the power supply terminal to the 5V+ DC terminal on the E5X. Use the black wire to connect the COM terminal on the power supply to the GND terminal on the E5X (Red → +V1/5V+, Black → COM/GND).

Step 3:  Take 1 metre of DC Cable – 2 Core – 2mm (Red and Black Wire), use the red wire to connect the +V2 output of the power supply terminal to the 24V+ DC terminal on the E5X. Use the black wire to connect the COM terminal on the power supply to the GND terminal on the E5X (Red → +V2/24V+, Black → COM/GND).

Step 4: Ensure that all terminals are well tightened before moving to next steps. It is important that all connections are well secured to their respective terminals.

The image below shows the 5V and 24V terminals of the Mean Well RD-65B series 66W Dual Output.

Click to expand

Pro Tip: We highly suggest crimping or soldering the end of your wires for the best connection. To crimp the wires correctly follow the below steps:

Step 1: Take the wires and strip the ends using a wire stripping tool.

Click to expand

Step 2: Twist the copper strands of each wire gently as shown on the left image below. 

Click to expand

Step 3: Place a spade terminal on twisted strands of each wire and crimp using a crimping tool to make a good connection.

3.1 Wiring – Multiple Power Supplies

Since E5X uses a Dual Output Power Supply and the motors use a separate power supply, it is essential to connect the common grounds of both the power supplies together to prevent floating voltages and erratic behaviour of the system. 

If you are using 2x Power Supplies (one for the motors and one for the controller – Dual Output Power Supply), connect their Common Grounds together as shown in the image below 

Type 1
Click to expand

If you are using more than one power supply for the motors and a Dual Output Power Supply for the E5X controller, connect their Common Grounds as shown in the image below: 

Type 2
Click to expand

4.0 Wiring – The E5X to Motor Drivers

The wiring for all motor drivers/stepper drivers is nearly identical using the motor drivers’ Step(ST)/Pulse(PUL) and Direction (DIR) signal interface. One of our E5X Bundles uses 3 Servo Motors (one each for X,Y and Y2 Axis) and a Stepper Driver (for Z-Axis). 

Connect your E5X to the motor drivers/Servo Motors by following the recommended Common Anode method detailed below

Click to expand

Step 1: Loosen the terminals of the “Motor Output” Axis ( for example X-Axis) of the E5X controller board and the motor driver.

Step 2: Use a 2 Core Cable 7/0.2 (Blue and White Wire) to connect the PUL+ and DIR+ of the stepper driver to the ST and DR of the particular axis mentioned on the E5X respectively (White → PUL+/ST, Blue → DIR+/DR).

Note: You will receive 4m of 2 Core Cable 7/0.2, use 1m per stepper motor driver.

Step 3: Use Hook Up Cable – 1 core (Black wire) to connect PUL- and DIR- on the motor driver.

Note: You will receive 4m of Hook Up Cable – 1 core, use 1m per stepper motor driver.

Step 4: Run another Hook Up Cable – 1 core (Black Wire) from DIR- to the GND of the motor driver.

Step 5: Ensure all the terminals are well tightened to have a proper connection. Below images show the wiring for X-Axis Motor Driver to the E5X.

Step 6: Repeat the above steps for all the motor drivers to connect them to their respective Motor Output Axis on the E5X.

Click to expand

Note: The Enable (EN) feature of the E5X powers down the associated stepper motor to allow manual movement of the respective axis gantry. The Enable feature does not need to be connected for the machine to function. If you choose to omit this connection, the gantry can be manually moved by switching off the machine.

Since a Servo motor has built-in drivers, the wiring for the same is different from open loop and closed loop motor drivers. Identical to the wiring for the Closed Loop Stepper Drivers, Servo Motor wiring for the X, Y, and Y2/A-axis is done using the common anode method. For our machines, a servo motor is not used for the Z-Axis.

Step 1: Loosen the terminals of the “Motor Output” Axis ( for example X-Axis) of the E5X controller board.

Step 2: Use a 2 Core Cable 7/0.2 (Blue and White Wire) to connect the PUL+ and DIR+ of the Servo motor to the ST and DR of the particular axis mentioned on the E5X respectively (White → PUL+/ST, Blue → DIR+/DR). 

Step 3: Use a Hook Up Cable – 1 core (Black wire) to connect PUL- and DIR- on the Servo motor.

Step 4: Run another Hook Up Cable – 1 core (Black Wire) from DIR- to the GND of the Servo motor. Above image shows the wiring of a Servo motor to the E5X.

Step 5: Ensure all the terminals are well tightened to have a proper connection.

Step 6: Repeat the above steps for all the Servo motors to connect them to their respective Motor Output Axis on the E5X.

As an example, the wiring of a NEMA23 180W Integrated Servo Motor with the E5X has been shown below

Click to expand

Pro Tip: We highly suggest crimping and using Ferrule Terminals on the end of your wires for the best connection. To attach Ferrule Terminals to the wire ends, please follow the below steps.

Step 1: Take the wire and strip the ends using a wire stripping tool

Click to expand

Step 2: Twist the strands of each wire gently and place ferrule terminals on each wire as shown below

Click to expand

Step 3: Using a crimping tool, attach the ferrule terminals to the wire ends.

Click to expand

4.1 Motor Drivers to Stepper Motors Connections

The wiring for all motor drivers is nearly identical using the motor drivers’ Step/Pulse (ST/PUL) and Direction (DIR) signal interface. 

Note: Use the Shielded 4 Core Cable 7/0.5 – High Current (as an extension cable) to connect stepper drivers to the stepper motors

4.1.1 Open Loop Stepper Motor – DM556 Driver Wiring

The DM556 stepper motor driver supports speed and direction control for ease of use in CNC, robotics and hobbyist applications. You can set its micro-step and output current via the 8 DIP switch array. All signal terminals are opto-isolated, reducing the chances of interference.

Click to expand

4.1.1.1 DM556 Driver Settings

Use the below DIP switch settings for the DM556 Driver:

SW1SW2SW3SW4SW5SW6SW7SW8
ONOFFONOFFOFFOFFONON
4.1.1.2 Reversed Y2/A Wiring

On a belt or rack and pinion driven system, directional motion is made by a motor turning a gear on a toothed track. As the Y2-Axis (or A-Axis) mirrors the Y-Axis, the motor direction must also be reflected, not copied. Therefore, the Y2-Axis motor needs to be reversed when using a belt or rack and pinion system.

Below is a wiring diagram of how this can be achieved on the DM556 Stepper driver.

Click to expand

4.1.2 Closed Loop Stepper Motor – HBS57/HSS57 Driver Wiring

Maker Store supplies two types of Hybrid Servo Drivers; the 8-dip switch HBS57 and the HSS57. Both are wired identically, but have slightly different settings.

Click to expand

Click to expand
4.1.2.1  Closed Stepper Motor Driver Settings

HBS57

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Below are the DIP switch settings for a HBS57 driver configured for a NEMA23 motor with 1/8th step micro stepping and turning clockwise.

SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
ON OFF ON ON ON ON OFF ON

If you are using a NEMA24 motor, follow the below DIP switch settings:

SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
ON OFF ON ON ON ON ON OFF

For Reversed Y2-Axis Stepper Driver, note the change for SW5: ON = CCW, OFF = CW.

HSS57

Click to expand

Below are the DIP switch settings for the HSS57 Stepper Driver:

SW1 SW2 SW3 SW4 SW5 SW6
OFF ON ON OFF ON ON

For Reversed Y2-Axis Stepper Driver, note the change for SW2: ON = CCW, OFF= CW.

4.1.3 Servo Motors

Click to expand

Servo Motors motors are high-performance motors that have a built-in encoder for position feedback with the ability to recover missed steps. They also have alarm outputs to indicate faults in the motor system. Servo motors have built-in drivers which is an ease for the user as no separate connections are required.

4.1.3.1 Servo Motor Settings

Servo Motors have dip switches directly on their in-built encoders. Below are the DIP switch settings for our NEMA23 180W Integrated Servo Motor:

SW1 SW2 SW3 SW4 SW5 SW6
ON OFF ON ON OFF ON

For Reversed Y2-Axis motor, note the change for SW6: OFF = CW, ON = CCW.

5.0 Limit Switch Wiring

Limit switches vary in shape, size and mode of operation, but the functionality is generally the same. When the circuit completes (Normally Open) or disconnects (Normally Closed), a signal is sent to the controller to indicate a limit has been reached. 

In a Normally Open (NO) configuration, the controller reads a low signal (0V) as normal operation and a high signal (24V) as a limit switch trigger

In a Normally Closed (NC) configuration, the controller reads a high signal (24V) as normal operation and a low signal (0V) as a limit switch trigger

Normally Closed configurations are recommended as the user will be notified when a fault is detected in the wiring, preventing machine axis’ collisions.

5.1 Mechanical limit switches

Mechanical Limit Switches trigger when an actual contact is made by the machine or a moving part of the machine with an operating lever or an actuator. Wire the limit switches to the E5X using the Normally Closed (NC) configuration detailed below.

Click to expand

Step 1: Terminate the 2 Core Cable 7/0.2  (Blue and White) cable with a suitable spade terminal or solder the stripped cable to the NC (Blue) and C (White) terminals of the mechanical limit switch.

Note: You will receive 12m of 2 Core Cable 7/0.2  cable, use 3m per machine axis.

Step 2: Loosen the SIG and GND terminal of the appropriate E5X LIMIT SWITCHES INPUTS axis, insert the Blue (NC) cable into the SIG port and the White (C) cable into the GND port (Blue SIG, White GND)

Step 3: Tighten the terminal to ensure proper connection.

Pro Tip: Terminate the E5X cable ends with Ferrules for a more secure connection.
 

Note: 

  • Follow the above wiring diagram. Incorrect wiring can blow the fuse and damage the circuitry. 
  • Use a shielded 2-core cable to minimise chances of EMI (Electromagnetic Interference) triggering the limit switches. The cable shielding (mesh wire surrounding the core wires) must be terminated to the Earth (⏚) of the 24V power supply.

6.0 Wiring –  The E5X Signals to VFD

Important
It is essential to check your VFD and Spindle manuals before connecting as incorrect wiring can cause failure. This instruction set is for the Folinn BD600 VFD, please consult your VFD manufacturer for wiring instructions.

Enabling and controlling the spindle with the E5X requires connection via a VFD. Outputs from both SPINDLE-AN and SPINDLE-DIG are used to fine tune the spindle speed. For initial setup using our Folinn BD600 Series VFD, we suggest the following wiring:

Click to expand

Step 1: Loosen the terminals of the “SP-EN” and “0-10V” ports on the E5X controller board and the “S1”, “AI1”, “DCM” and both “ACM” ports of your BD600 series VFD (See the image above).

Step 2: Use a Shielded 4 Core Cable 14/0.2 (Red, Green, Blue and Yellow Wire) to connect the VFD signal outputs to the E5X using the table below:

VFDE5X MCS Controller
S1SP-EN – SIG (GREEN)
ACM(1)SP-EN – GND (BLUE)
AI10-10V – SIG (RED)
ACM(1)0-10V – GND (YELLOW)
ACM(2) to DCM (BLUE) –

Note: You will receive 2m of Shielded 4 Core Cable 14/0.2 for the above VFD connections.

Step 3: Use a Hook Up Cable – 1 Core 0.5mm – Blue for the ACM(2) to DCM “jumped” connection.

Note: You will receive 1m of Hook Up Cable – 1 Core 0.5mm – Blue to complete ACM/DCM VFD bridge.

Step 4: Tighten the terminals to ensure proper connection.

0-10V is the most commonly utilised signal for spindle speed control. 4-20mA is commonly used where long cable is required between the VFD and the E5X controller to reduce signal loss. 4-20mA signals can offer increased immunity to Electromagnetic interference (EMI) from other devices.

Note: This connection is only recommended if the analog input circuitry of the VFD is isolated from the high voltage part of the VFD.

0-10V Method:

Connect SIG from the 0-10V terminal to the analog input (AI1) signal terminal on the VFD and GND to the analog ground terminal (ACM) on the VFD.

 

DescriptionE5X MCS T41 TerminalVFD TerminalFunction
Spindle Speed Signal – Voltage
SIGAI1
Varies speed of spindle from min to max using Voltage.
GNDACM
 
Click to expand

6.1 Folinn BD600 VFD Programming Parameters

Program your Folinn BD600 VFD using the following commands:

Initially Reset the VFD to factory default setting settings by setting F00.28 = 1

  • Frequency Reference Resolution
    • F00.11 = 1
  • Speed Control Mode
    • F00.00 = 2
  • Command Source Selection
    • F00.01 = 1
  • Max Output Frequency
    • F00.03 = 400.00
  • Run Frequency – Upper Limit
    • F00.04 = 400.00
  • Run Frequency – Lower Limit
    • F00.05 = 133.00
  • Frequency A command selection
    • F00.06 = 2
  • Keypad Setting Frequency
    • F00.10 = 400
  • Acceleration time 1
    • F00.12 = 5
  • Deceleration time 1
    • F00.13 = 5
  • Motor Rated Power: (Ensure that you choose the correct motor power rating for your spindle)
    • 1.5kW: F02.01 = 1.5
    • 2.2kW: F02.01 = 2.2
  • Motor Rated Frequency
    • F02.02 = 400
  • Motor Rated Speed
    • F02.03 = 24,000
  • Motor Rated Voltage
    • F02.04 = 220
  • Motor Rated Current: (Ensure that you choose the correct motor current for your spindle)
    • 1.5KW: F02.05 = 7
    • 2.2kW: F2.05 = 9

  • Forward/Reverse: 2 Wire Control:
    • F05.13 = 1
  • VFD Display RPM
    • F07.03=0011
  • Decimal Points for Speed Display
    • F07.12=0

7.0 Wiring – Outputs Touch Probe

The Touch Probe is designed to sit off the corner of the workpiece, allowing the user to position the X and Y zero coordinates and the Z zero coordinate accurately and easily.

Click to expand

To wire the touch probe, plug the following wires into the DIGITAL INPUTS – PROBE ground (GND) and (SIG) ports and connect the probe as suggested in the Touch Probe Listing.

E5X PortTouch Probe
PROBE – GNDAlligator Clip (Red)
PROBE – SIGGND (Black)

Step 1: Insert the stripped cable of the red/black DC Cable – 2 Core wire into the non-tapped hole of the Touch Probe Plate. Ensure it is all the way in.

Step 2: Insert the M3 set screw into the tapped hole and tighten it onto the inserted wire. Ensure it is making good contact (Don’t tighten so hard that you break the wires). Make sure that it is securely fixed in the terminal by gently pulling on the cable.

Step 3: Place your Touch probe on the corner of the workpiece where you would like to set 0, 0, 0.

Step 4: Activate your machine and manually jog the machine to the middle of the touch probe about 5mm off of the probe’s surface.

Step 5: Attach the alligator clip (red) to your endmill.

Step 6: Use the relevant software to begin the probing process and therefore zero your workpiece.

Step 7: To extend the length of your touch probe’s wire, attach a second length of DC Cable – 2 Core wire to a 2-Pin EDG 3.81mm terminal, connecting the original DC Cable – 2 Core wire to the opposite 2-Pin EDG 3.81mm terminal. Make sure the Red and Red/Black wires are lined up correctly over the 2-Pin EDG 3.81mm connections.

8.0 Motor Driver Power Connections

The number and type of power supplies required for stepper/servo motors depend on the machine size. In order to connect the stepper motor drivers/servo motor to the power supply, follow the respective section:

If you are using DM556 Stepper Drivers, click here 

If you are using HSS57/HBS57 Stepper Drivers, click here

If you are using Servo motors, click here

8.1 DM556 Stepper Driver to 450W/600W Power Supply

DM556 stepper drivers are used for open loop motors. For best performance, we recommend using a 36V Power Supply and Open-loop NEMA23 Stepper Motors with these drivers. 

For illustrative purposes, the wiring diagrams for four DM556 Digital Stepper Drivers with a Mean Well 450W Power Supply or a Mean Well 600W Power Supply have been shown below. Depending on your power supply, please follow the respective wiring diagram.

1x 450W Power Supply
1x 600W Power Supply

Click to expand

Follow the below steps to connect  DM556 Stepper Drivers to a 450W/600W Power Supply:

Step 1: Loosen the +V and GND terminals of the DM556 stepper driver and +V and -V terminals of the 450W/600W power supply.

Step 2: Use a DC Cable – 2 Core 3mm (Red and Black wire) and run the black wire from the GND of the DM556 Stepper Driver to the V of the 450W/600W power supply.

Step 3: Run the Red wire of the same DC Cable – 2 Core 3mm from the +V of the DM556 Stepper Driver to the +V of the 450W/600W power supply. For reference see the images above.

Note: You will receive 4m of DC Cable – 2 Core 3mm, use 1m per stepper driver.

Step 4: Tighten the terminals to ensure proper connection.

Step 5: Repeat the same steps for all other DM556 Stepper drivers.

For illustrative purposes, the wiring of a DM556 Stepper Driver with a Mean Well 450W Power Supply has been shown below. The wiring is identical for a 600W Power Supply.

Click to expand

The 450W Power supply + DM556 Stepper Drivers are best suited for 1.26Nm/2.45Nm open loop NEMA23 stepper motors, whereas the 600W Power supply + DM556 Stepper Drivers are best suited for the 3.0Nm open loop NEMA23 stepper motors.

8.2 HSS57/HBS57 to 450W/600W Power Supply

HSS57 and HBS57 stepper drives are closed-loop stepper motor drivers that can control NEMA23 and NEMA24 closed-loop stepper motors. For best performance, we recommend using a 36V Power Supply with these drivers. 

Wiring diagrams for four HBS57/HSS57 Stepper drivers with dual Mean Well 450W Power Supplies or Mean Well 600W Power Supply have been shown below. Depending on your power supply, please follow the respective wiring diagram.

2x 450W Power Supply
1x 600W Power Supply

Click to expand

Note: The wiring for both the HSS57 and HBS57 Stepper drivers are identical.

Follow the below steps to connect HSS57/HBS57 Stepper Drivers to 450W/600W Power Supply:

Step 1: Loosen the +Vdc and GND terminals of the DM556 stepper driver and +V and -V terminals of the 450W/600W power supply.

Step 2: Use a DC Cable – 2 Core 3mm (Red and Black wire) and run the black wire from the GND of the HBS57/HSS57 Stepper Driver to the V of the 450W/600W power supply.

Step 3: Run the Red wire of the same DC Cable – 2 Core 3mm from the +Vdc of the HBS57/HSS57 Stepper Driver to the +V of the 450W/600W power supply. For reference see the images above.

Note: You will receive 4m of DC Cable – 2 Core 3mm, use 1m per stepper driver.

Step 4: Tighten the terminals to ensure proper connection.

Step 5: Repeat the same steps for all other HBS57/HSS57 Stepper drivers.

For illustrative purposes, we have shown below the wiring of an HSS57 Stepper Driver with a Mean Well 450W Power Supply. For a 600W Power Supply, the wiring is identical.

Click to expand

600W Power Supply + HSS57/HBS57 Stepper Drivers are best suited for 2.0Nm NEMA23 closed loop stepper motors, while the 2x 450W Power supply + HSS57/HBS57 Stepper Drivers are best best suited for 3.0Nm NEMA23 closed loop stepper motors.

8.3 180W Integrated Servo Motor to 2x 450W Power Supply

NEMA23 180W Integrated Servo Motors are high-performance brushless DC servo motors with integrated drivers. Wiring these servo motors to a power supply is simple; Power Supply +V and -V to Servo Motor DC+ and GND respectively. Two 450W Power Supplies are required for a four-motor setup. 

For illustrative purposes, the wiring of NEMA23 180W Integrated Servo Motors with a Mean Well 450W Power Supply has been shown below.

Click to expand

Follow the below steps to connect Servo Motor to a 450W/600W Power Supply:

Step 1: Loosen the DC+ and GND terminal connectors of the Servo motor and +V and -V terminals of the 450W/600W power supply.

Step 2: Use a DC Cable – 2 Core 3mm (Red and Black wire) and run the black wire from the GND of the Servo motor to the V of the 450W/600W power supply.

Step 3: Run the Red wire of the same DC Cable – 2 Core 3mm from the +DC of the Servo motor to the +V of the 450W/600W power supply. For reference see the image above.

Note: You will receive 3m of DC Cable – 2 Core 3mm for Y-Axis, 5m for Y2-Axis and 5m for X-Axis.

Step 4: Tighten the terminals to ensure proper connection.

Step 5: Repeat the same steps for all other servo motors.

9.0 Emergency Stop Switch Wiring

The purpose of an emergency stop switch is to quickly and safely halt the operation of a machine if someone’s safety or the safety of the equipment is at risk. 

When the emergency stop switch is pressed or activated, power to the machine is immediately cut off, bringing the operation to a safe stop. It is important to note that once the emergency stop switch is activated, the machine must be inspected and repaired before it can be restarted to ensure that it is safe to operate again.

To access the terminals of the Emergency Stop Switch, unscrew the 4 screws of the switch housing using a Phillips screwdriver.

Important
The Emergency Stop Switch needs to be wired on the mains voltage section of the machine/setup. This wiring needs to be done by a Licensed Electrician or a similarly qualified individual only.

Click to expand

10.0 Software Configuration Guide

The E5X requires a G-Code sending software to control the outputs and execute instructions based on the G-Code. Below is the setup guide for different modes of operation.

10.1 Setup in ioSender

Download ioSender
To interface with the controller, you will need a G-Code sending software. There are many types of G-Code senders available, but we highly recommend ioSender. It is a powerful G-Code sender used for CNC control with a feature-rich and easy-to-use interface.

ioSender can be downloaded here. Be sure to download the latest release.

  • Locate the downloaded file. By default, it should be in your Downloads folder.
  • Unzip the downloaded file and copy the folder to your desktop.
  • Open the folder and locate ‘ioSender.exe’. Double-click the file to open it. It will initially launch with the following screen.
Click to expand

Brief Intro to ioSender:
ioSender is the recommended G-Code sender for use with the E5X controller. It allows for easy machine configuration and advanced functionality to improve workflow.

The following ioSender Screen will pop up when you run the software. The main aspects of the program have been highlighted for you.

Click to expand

Configuring ioSender:
Before first use, it is recommended to adjust a few parameters of the software. The main adjustments are shown below, highlighted by the green square. After adjusting the parameters, click the “Save Settings” button highlighted by the red square:

E5X-NEW-_12_
Click to expand

10.2 USB Setup

10.2.1 USB Selection Guide

For connectivity, a USB type A to type USB type B cable is required. As USB can be susceptible to EMI from devices such as spindles, it is highly recommended to keep the cable as short as possible and use a USB cable with shielding and ferrite cores built into the cable as shown below.

USB type A to Type B Cable with built-in Ferrite Core

Click to expand

The E5X uses a Silicon Labs CP2102 USB UART bridge to communicate with ioSender. To use the USB connection, you will need to install the CP2102 USB drivers. See below for the installation instructions.

  1. Download and install the CP210x drivers here:
  2. Extract the file and run:
    • CP210xVCPInstaller_x64 if you have a 64-bit computer
    • CP210xVCPInstaller_x86 if you have a 32-bit computer

To communicate with ioSender via USB, open ioSender and select the Serial tab. In the Port drop-down box, select the correct port with Silicon Labs CP210x USB to UART Bridge. Please note, your port will likely differ from the one shown in the example. 

By default, the Baud rate is set to 115200 bits per second. This value should not be changed as it will affect the E5X performance. 

The On connect behaviour should be set to No action.

Selecting “Ok” will launch ioSender and you will have full access to CNC machine controls.

Click to expand

10.3 Ethernet Setup

The E5X MCS uses a Texas Instrument DP83825I 10/100-Mbps Ethernet PHY transceiver to communicate with ioSender. Ethernet communication is made through a direct connection between the E5X and an ethernet-enabled computer. No switching devices like a router or ethernet switch are required for a direct PC connection.

A standard RJ45 cable is used to make the connection.

RJ45 Ethernet Cable

The ethernet connection is most recommended as it is highly resistant to EMI. Ethernet cables have twisted pairs that reject interference from external equipment like VFDs and Spindles. The ethernet configuration needs to be made in two places; in ioSender and in the computer’s network settings. The parameters that need to be changed are the following:

E5X Network Parameters:

  • IP address
  • Gateway
  • IP Mode

Computer Network Parameters:

  • IP address
  • Gateway

Below is the guide for changing these parameters, it is imperative that your network settings are the same as the ones in this guide.

10.3.1 Set up Network on the E5X MCS

Each E5X controller comes pre-flashed with the network settings pre-set. The settings are as follows;

  • IP address: 192.168.5.1
  • Gateway: 192.168.5.1
  • Hostname: GRBL

The network settings can be set in ioSender in the networking menu. Click on each of the settings and set the parameters as shown above. Click Save after make the changes and restart the controller for the changes to take effect.

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10.3.2 Set up Network on the computer

To set up the network connection enter ‘Network Status’ in the Windows Search bar. Click on the View Network Status and Tasks pop-up. 

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The Network and Sharing Center will show. Click on Change adapter settings as shown by the green square. 

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A list of networks will show. Right-click the Ethernet option and select Properties. The Ethernet Properties will show.

The current Ethernet properties will show. Left-Click on the Internet Protocol version 4 (IPv4) and select Properties.

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Click Use the following IP address checkbox and set the IP Address to the following:

  • IP Address: 192.168.5.5

Change the Subnet Mask to the following:

  • Subnet Mask: 255.255.255.0

Click the Validate settings upon exit checkbox and then click OK

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Close the Ethernet Properties dialogue box. 

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The ethernet properties have now been set on your computer, please proceed to the following section to configure ioSender communication with E5X MCS controller via ethernet.

10.3.3 Configure ioSender to Communicate via Ethernet with E5X Controller

To launch the E5X MCS in ethernet mode, open ioSender and click on the network tab. Check that the port is set to 23 and the IP address is set to 192.168.5.1. 

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10.4 Machine Configuration For Maker Store Machines

Machine configuration for Maker Store machines is quite straightforward. Machine configurations have been created and contain recommended settings for the controller and machine. The user can choose to adjust settings such as motor speed and acceleration to suit. 

The machine configuration process is outlined below:

  • Download our Machine Configuration files here.
  • Unzip the Master Config file. This config file has some folders corresponding to each of our machines. If you have a custom machine or a different brand of machine, contact us at sales@makerstore.com.au and our technicians will be able to assist you with your machine.
  • Navigate to the folder containing the brand of the machine series you own. The image below shows the list of machines in our inventory. For example, if you own an OutBack 1000 x 1000mm kit, navigate to the OutBack CNC folder.
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  • Copy this file and paste it into the main ioSender folder of your documents folder. In this example, we copied it into the main ioSender folder. 
  • Load ioSender and click the ‘Settings:Grbl’ tab highlighted by the red arrow below. 
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  • The settings menu will load. Click on the Restore button highlighted by the red arrow in the bottom right corner. 
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  • A window will load and prompt you to select the machine configuration file. By default, the window will search in the main ioSender folder. Navigate to the folder that you saved the machine configuration file in. As we saved it in the main ioSender folder, we will select the file and click the Open button highlighted by the red arrow.
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  • The profile will load and the window will close automatically. Click the save button indicated by the red arrow. 
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  • The machine configuration has now been loaded. Jog the motors using the jog panel to check the motor direction. Homing can be set up here

10.5 Machine Configuration For Custom Machines

Depending on the type of machine you have, the motor settings will need to change to suit. The settings that affect the performance of the machine are the following;

  • Steps per mm
  • Acceleration
  • Maximum Feed rates
  • Maximum Travel
  • Motor direction
Adjust the motor parameters to suit your machine by navigating to the appropriate motor-specific settings.
 

Motor-Specific Settings:

These settings determine the general behaviour of the motors and can be found in the Stepper submenu. After changing the settings click save button.

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Axis-Specific Settings:

These settings determine the general behaviour of the motors and can be found in the Axis submenu.

The image below depicts the X-Axis specific settings. You will need to modify the parameters to suit your machine axis requirements and click save button for the changes to take into effect.

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10.6 Tuning Motor Direction

You may need to change the motor direction in software depending on the way the motors were installed/configured. While this may be changed physically, it is quicker to configure motor direction in ioSender. 

Please note: A cloned motor (via clone jumpers) can not have its direction done via software. It must be configured via the appropriate wiring sequence. 

In Grbl:settings navigate to the Stepper menu and select Step direction invert. All motor axis will be displayed here and you can choose which motor to select.

Press save button to save any changes and jog the motors to test.

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10.7 Homing/Homing Direction

Homing is a function that sets the zero or reference position of every axis of the machine. This reference can be used alongside job fixtures and work offsets.  Homing involves the machine moving towards the location of limit switches, which is user dependent. Homing can be very helpful to improve one’s workflow.

In the Settings: Grbl navigate to the Limits settings and tick the Hard Limits Enable box. This will enable the limit switches.

In the Settings: Grbl under Homing, tick the Homing Cycle Enable checkbox to initiate homing of the machine.

Enabling the homing cycle will enable the machine to be homed when the homing command has been issued to the E5X MCS. See the image below to enable the homing cycle

WM-8.3.2-Enable-Limit-Switches-1
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WM-8.6.1-Enable
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After enabling the limit switches and homing cycle, click the save button.

In the main menu, clicking Home or entering in $H will see the machine initiate the homing sequence by moving towards the limit switches.

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If the machine is not moving towards the limit switches, take note of the axis moving away from limit switch and abort the homing cycle by pressing the red RESET button or if you have a physical button interface connected to the E5X MCS, press the emergency stop button.

In the Settings: Grbl navigate to the Homing menu to change the homing direction settings for the axis that is moving away from the limit switch. Click Save for the changes to take effect.

WM-8.6.3-Homing-Direction-Invert
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After changing the homing direction for respective axis, click save button for the changes to take into effect.

11.0 Add-Ons – Not Required for Most Users

11.1 Clone Axis

The E5X  comes with the Y-Axis cloned by default, this configuration can be changed using the following process:

Step 1: Unscrew the M3 Bolts on top of the controller case using a 2.0mm Allen key and gently pull off the case.

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Step 2: Locate the shunts and gently remove them from STEPY, ENY and DIRY as shown in the highlighted red rectangle below.

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Step 3: Place the removed shunts in the desired axis location, for example STEPB, ENB and DIRB as shown in the images below.

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Step 4: Ensure that the shunts are correctly seated in their respective locations.

11.2 Inductive Limit Switch Wiring

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Inductive proximity switches trigger when a circuit completes electronically. To complete this electronic circuit, the inductive proximity switch needs to come into contact with a metallic surface such as steel or aluminium. Inductive switches perform best when in contact with ferrous (magnetic) metals such as steel.

Note: 

  • Observe the wiring sequence on the inductive proximity switch. Incorrect wiring will damage the inductive sensor. 
  • Use a shielded 3 core cable to minimise chances of EMI triggering the limit switches. The shield of the wire must be terminated on one side to GND on the 24V power supply.
  • The Inductive proximity switches have a working voltage range. Ensure that your Inductive proximity switch is in the 24V range.
  • NPN NC limit switches are recommended for use with the E5X.
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E5X MCS Controller Inductive Proximity Switch
24V 24V (BROWN)
SIG Signal (BLACK)
GND GND (BLUE)

11.3 Wiring – E5X to Alarm Input Signals

The E5X utilizes this alarm signal to stop a program or arrest the motion of the machine, preventing damage to the system or workpiece.

To wire the alarm outputs from the alarm source, an external pull-down resistor must be used in order to eliminate false-triggers from electrical noise..

  • For 5V systems, use a 2K resistor to pull down the 5V line.
  • For 24V systems, use a 10K resistor to pull down the 24V line.
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Wiring the alarm signals involves wiring the positive(+) Alarm pins on the E5X board to the negative(-) Alarm pins on the stepper motor driver or servo. The resistor must be wired between the E5X positive(+)  and GND.  Furthermore, the E5X negative(-) Alarm pins must be connected to GND. The stepper motor alarm positive(+) pin must be wired to 5/24V power. 

 

E5X MCS Axis –Resistor
E5X MCS Axis +GND
Stepper Driver +24V
Stepper Driver –E5X MCS Axis +

Links and Credits

Special thanks to:

PRJC – Teensy
The E5X Motion Controller was designed to use the Teensy® 4.1 Development Board as the microcontroller. Maker Store is an authorised distributor of PJRC’s Teensy® 4.1 Development Board. PJRC are the designers, producers and owners of all Teensy brands and logos.

The grblHAL community

The Maker Community
Special thanks to our fantastic Maker Community whose  feedback helps provide new ideas and innovation for us to design and produce to make available back to the community.

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