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Advanced Electrical Discharge Machining (EDM) D.I.Y. Project
Chu's Engineering Services (CES)



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Gen4 Main Console 60A Max

12"(H) x 6"(W) x 12"(D)
Dual 6"x6" faceplate
12" Heasink backplan
Advanced Air-flow Management
Dual 2004A LCD Display
PWM 50Hz-50KHz 1-95% Duty
Manual Override EDM Mode
12V/24V 3A Z-Axis Driver Select
Z-Axis Speed/Resolution Adj
4x 15A PWM Output PowerPaths
Path's Output Level Adj
EDM Status and controls
1x Cascade Output
1x Expansion Output
2x Controls input
Dual AC Input Circuit
Dual 480W/720W PS Mounts
Inner/Heatsink Temperature Readout
AC Input Power Monitoring

The EMP4 is the largest Main Console in Gen4 series, equipped with dual ATmega328 microcontroller via 2x onboard Arduino Promini module. Basic hardware configuration using 180325 PCB has dual 2004A I2C LCD (can add many in parallel as needs) port, multiple Temperature readout (Inner-Air, Heatsink) using DS18B20 Temp. Sensor, 2x DVM (Vin and Vprobe), 1x DAM (EDM Current), 1x PWM output (phase-correct 16-bit PWM 30~50K Hz 1~95% Duty), 3x Hi-side, 3x Lo-side MOSFET Drivers, Logic I/O includes EDM probe sensing, 12V/24V Stepping Motor interface, key switch inputs, Top/Bottom/End position detect and LED indicator drivers which all controls via firmware and highly customizable.
The EMP4 has 2x side mounts 480W/720W LED Strip power supply and 4x 15A limited PWM output circuit that provides up to 60A at 24VDC of the continue output power (depend on in use PS rating). Additional power obtains via Expansion Console EXP4, Cascade Console ECP4 as desired.
Distilled Water were use as EDM dielectric fluid bath between Probe and work piece.

System Block Diagram |  |
Console Assembly Illustration |  |
Console Views Illustration |  |

CPU Board 180325-3 Schematics |  |
CPU Board 180325-3 PCB Assembly |  |
Main Power Board 180322-3 (xH) Schematics |  |
Main Power Board 180322-3 (xH) PCB Assembly |  |
AUX Power Board 180322-4 (xL) Schematics |  |
AUX Power Board 180322-4 (xL) PCB Assembly |  |
I/O Board 180503-1 Schematics |  |
I/O Board 180503-1 PCB Assembly |  |

CPU Board 0325 PWMGen Promini 1 |  |
CPU Board 0325 ZDRV Promini 2 |  |

Case Top Panel |  |
Case Bottom Panel |  |
Case Left Panel |  |
Case Right Panel |  |
Case Front Panel (upper) |  |
Case Front Panel (lower) |  |
Case Front Bar |  |
Case Horizontal Bar |  |
Heatsink Backplane |  |

PS Sub Assembly |  |
Heatsink BP Assembly |  |

Bill Of Meterial
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Image Slides
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Note: All contents subject to change without prior notice.

Update: November 2018


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