Tag: Improvements

Having picked up a small rotary intended for Ortur diode laser machines during Black Friday, I knew using it with my OMTech 60 W CO₂ laser wasn’t going to be plug-n-play. The usual connection for a rotary in a CO₂ laser is directly into the stepper motor driver for the Y axis, so the stepper motor in the rotary must handle the same current as the Y axis motor. The OMTech laser has NEMA 23 steppers set for 3.5 A, which would quickly fry the NEMA 17 stepper in the Ortur rotary.

So the general idea was to run the rotary from another stepper driver set for an amp or so. A separate driver would also let me choose microstep settings more suitable for a rotary.

A simple SPDT switch enables the appropriate driver:

NB: Leaving the ENA pins of a stepper driver disconnected enables the motor output and passing current through them disables the motor; why that function was not labeled DISABLE remains a mystery.

So the switch looks bassakwards, but it connects the -ENA pin of the disabled driver to GND / common, with its +ENA pin tied to the supply.

Translating that doodle into hardware required drilling holes in what passes for the laser’s front panel:

The new driver stands up in bottom of the electronics bay:

The loose wire over on the left is a remnant of the discovery that the KT332N controller’s General output bits do not behave as expected. While you (well, I) can set their state through the display’s MENU → DIAGNOSES screen, the controller unilaterally slams them low = active while running a job. To be fair, the manual does say “General output, reserved”, but I had to find out the hard way.

The +ENA terminal comes from the +5V supply, along with the other + terminals. The -ENA terminal goes off to the switch, along with two wires from the existing Y axis stepper driver:

The 1.8 kΩ resistor sticks out of a ferrule doubled up in the 24V terminal feeding the driver and connects to a wire into the +ENA terminal. Two wires from the switch connect to the -ENA and GND terminals, join the -ENA wire from the rotary driver, and crawl through the machine to the front panel.

The new power supply on the far right completes the electronics bay installation:

Obviously, the wiring situation is completely out of control.

Up top, though, it looks like it grew there:

Now, to figure out the settings …

In the process of replacing the laser cutter’s OEM 24 V 6 A power supply with a 15 A supply, one of the two screws holding it in place remained stuck in the underlying sheet metal plate:

You can’t see either of the screws from that position, but they’re in the upper-left and lower-right corners. The offending screw is, of course, on the top, tucked between the top of the supply and the wire raceway. The bottom screw came out easily and I could maneuver the supply out of the way.

Vigorous persuasion involving a bent-nose pliers and muttering got the screw out and revealed the problem:

The reason why the screwdriver didn’t get much traction in the head also became obvious:

Folks on the LightBurn forum seem astonished when they discover their fresh-from-the-factory has loose screws, missing screws, and occasionally the wrong screws.

I always wondered where the switch pointed to by the conspicuous label might be:

Unlike most supplies, it’s inside the case:

After you spot it, you can also find it just below the tip of the arrow in the previous picture. I suppose putting it inside the case prevents it from being inadvertently flipped, but somebody had to dismantle All. The. Supplies. to flip that switch for the USA-ian market.

The dataplate also became visible:

You’ll recall the 5 V 2 A output was dedicated to the red-dot pointer drawing about 20 mA.

In contrast, the 24 V 6 A output handled:

• X axis stepper driver: 3.5 A peak
• Y axis stepper driver: 3.5 A peak
• U axis stepper driver: 5.1 A peak
• KT332N controller &c: 1 or 2 A
• Gantry LED strip: 0.25 A

The stepper drivers are set to drop the motor current by half when they’re idle, which means their load would be only around 6 A. That’s as delivered to the motor windings, with the power supply’s average current being lower by roughly the ratio between the motor’s rated voltage and the power supply voltage. The instantaneous peak current, however, is the sum of all those currents.

At some point I must measure all that, but for now I want to shoehorn a bigger supply in there to take care of the additional load of the rotary stepper driver, plus the existing platform lighting and improved electronics bay blower.

The OMTech 60 W laser has a 24 V + 5 V power supply for the stepper motors and, I had always assumed, the feeble LED strip light on the gantry:

The stepper motor driver settings, plus a few amps for the controller and suchlike, added up to something over 12 A, far more than the 24 V supply’s 6 A spec should produce. When I added the COB strip lights around the platform, I dropped a 24 V wall wart into the electronics bay to avoid abusing that poor supply:

For reasons to be described later, it’s now time to upgrade that 24 V power supply to a 15 A supply that’s been on the shelf for far too long. However, it does not have a 5 V output, so it’s also time to figure out how much 5 V power the laser really needs.

A quick measurement suggested the 5 V output delivered 20 mA to something. After convincing myself the multimeter was working and that the gantry LED strip was still lit, I finally tracked the wire pair to the red-dot pointer:

Yeah, a whole dual-output power supply for one red-dot laser module.

Conveniently, the KT332N controller has several 5 V outputs and the LIMIT terminal block even has a GND terminal on the other end:

Prying off the hot melt glue, extracting the red-dot pointer wiring from the raceway, crimping ferrules on a couple of jumpers, and deploying a pair of Wago connectors:

I am still not accustomed to the color code:

• Black = signal
• Brown = power
• Blue = GND

But it’s like that and that’s the way it is.

The red dot lit right up, the gantry LED strip obviously uses 24 V power, and I must shoehorn a slightly larger 24 V supply into the space currently occupied by the old supply.