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Advanced Electrical Discharge Machining (EDM) D.I.Y. Project
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Printed Circuit Boards


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181010 CPU PCB

The 181010 CPU Board (same as 181005 except PWM MOSFET Driver used) design target to a smaller version of EDM main console with one Atmega328 Promini Microcontroller module. It also can be used as a generic embedded instrumentation by remapping I/Os and modify the firmware as desire. Board size is 3.9” x 2.55” with matching mounting hole for both 1602 and 2004A I2C LCD display module back to back mounts, and secure to face plate via LCD display mounting holes. 6x Indicator LED and FT232RL 6-pins interface programing socket JP3 footprint located above LCD display allows external accessible thru front panel cut-outs.

The built-in I/O interface includes; System Reset switch, multiple DS18B20 Temperature interface, TB6560 Stepping Motor Driver interface, Motor Speed adjust Potentiometer interface, Eroding Probe and Discharge Current sensing voltage comparators, Sensitivity Potentiometer interface, 3x IR2101 provides 3x Hi-side and 3x Lo-side EDM PWM MOSFET drivers. Two stage voltage regulation was used. Operating voltage is +20VDC max (per IR2101 spec).

PWM Generator using multiple preset frequency and duty via firmware. The minimum operating voltage should be +3VDC about the installed 1st stage voltage regulator, which is +12VDC for 7809 or +15VDC for 7812. Primary power input connection JP1 support only one IR2101 U4, additional power feeds JP26 required for other 2x IR2101(s) in use. 500mA typical with 1A inrush operating current shall be considered for all power feeds.

6x 3x6mm mini push-button thru-hole (or SMD) footprints located below the 1602 LCD zone as on-board key inputs for testing purpose. These switches can be solder on the component side or solder side as desired.

On Promini extend 10pin header, A5, A4, VCC, GND configure to be I2C port for cross module communication and LCD display driver. A7 as Stepper Motor Speed adjustment 0-5V input via 5K POT and A6 PWM Frequency/Duty adjustment 0-5V input via 5K POT.

The PCB allows trim-to-fit as needs for smaller footprint and less functions. All on board components are thru-hole (none Surface Mount) for better thermal characteristic and easy handling.

181010_v01 Schematics |  |
181010_v01 PCB Assembly |  |
181010-1_v01 Schematics |  |
181010-1_v01 PCB Assembly |  |

181005 CPU PCB

The 181005 CPU Board design target to a smaller version of EDM main console with one Atmega328 Promini Microcontroller module. It also can be used as a generic embedded instrumentation by remapping I/Os and modify the firmware as desire. Board size is 3.9” x 2.55” with matching mounting hole for both 1602 and 2004A I2C LCD display module back to back mounts, and secure to face plate via LCD display mounting holes. 6x Indicator LED and FT232RL 6-pins interface programing socket JP3 footprint located above LCD display allows external accessible thru front panel cut-outs.

The built-in I/O interface includes; System Reset switch, multiple DS18B20 Temperature interface, TB6560 Stepping Motor Driver interface, Motor Speed adjust Potentiometer interface, Eroding Probe and Discharge Current sensing voltage comparators, Sensitivity Potentiometer interface, 2x IR2110 provides 2x Hi-side and 2x Lo-side EDM PWM MOSFET drivers. Two stage voltage regulation was used. Operating voltage is +20VDC max (per IR2110 spec). PWM Generator using multiple preset frequency and duty via firmware. The minimum operating voltage should be +3VDC about the installed 1st stage voltage regulator, which is +12VDC for 7809 or +15VDC for 7812. Primary power input connection JP1 support CPU logic section only. Additional power feeds JP19 required for 2x IR2110(s) in use. 500mA typical with 1A inrush operating current shall be considered for all power feeds.

6x 3x6mm mini push-button thru-hole (or SMD) footprints located below the 1602 LCD zone as on-board key inputs for testing purpose. These switches can be solder on the component side or solder side as desired.

On Promini extend 10pin header, A5, A4, VCC, GND configure to be I2C port for cross module communication and LCD display driver. A7 as Stepper Motor Speed adjustment 0-5V input via 5K POT and A6 PWM Frequency/Duty adjustment 0-5V input via 5K POT.

The PCB allows trim-to-fit as needs for smaller footprint and less functions. All on board components are thru-hole (none Surface Mount) for better thermal characteristic and easy handling.

181005_v01 Schematics |  |
181005_v01 PCB Assembly |  |
181005-1_v01 Schematics |  |
181005-1_v01 PCB Assembly |  |
181005-3_v01 Schematics |  |
181005-3_v01 PCB Assembly |  |

180503 I/O PCB

The 180503 I/O Interface board design to simplify system split wiring and signal routing between CPU board and system connectors. Board size is 3.9” x 1.8” with matching mounting hole for 1602 and 2004A LCD display module allows mount at the top of CPU board with standoffs.

It also use for adding interface, I/O signal conditioning, and splitting connections as needs. Addition drive blocks includes TC4420 Hi-Current Driver, Dual Opto-Isolator, and large bread boarding zone for customization.

Default function includes but no limit to provide point-to-point wiring between CPU Board to Expansion I/O Connector, Cascade I/O Connector, Z-DRV Control Input Connector, EDM-ON System Interface, Tx/Rx DCOM Interface, and System VCC outputs re-distributions.

The PCB allows trim-to-fit as needs for smaller footprint and less functions. All on board components are thru-hole (none Surface Mount) for better thermal characteristic and easy handling.

180503_v01 Schematics |  |
180503_v01 PCB Assembly |  |
180503-1_v01 Schematics |  |
180503-1_v01 PCB Assembly |  |
180503-2_v01 Schematics |  |
180503-2_v01 PCB Assembly |  |
180503-3_v01 Schematics |  |
180503-3_v01 PCB Assembly |  |

180502 PB Power PCB

The 180502 PB Power Board provides 15A current limited PWM current output of EDM power by design. The board size is 4.3" x 1.5", and mounting support by 4x on board power devices (1x TO247 MOSFET Q1 and 3x TO220 Schottky Diode D1, D2, D3) attach on to heatsink securely mounts. Thermal Pad and Isolation Bushing are require for power device(s) equipped with exploded metal tab on the body (Same mounting method as all previous PB Power board designs). On board Fuse is 5mm x 20mm 15A and all power connector is 3.5mm Mini Bullet Sockets in gold finish.

The primary Hi-side driver required isolated (floating) 12VDC 1A Power Supply on JP1, and 12Vp-p PWM input signal on JP3 to be operative. Use on board IR2110 to provides Lo-side input capability and cascade output if needed. JP5 floating DMM interface to 180501 CPU board for PWM Pulse current monitoring.

The maximum current on power path is 15A. Install 0.035 Ohms 10W minimum Current sensing resistor across RD1 and RD1, and 5K POT to JP4 to adjust the output’s limited current, or 4.7Kohm 1/4W resistor to set the output current, if POT not in use.

The PCB allows trim-to-fit as needs for smaller footprint and less functions. All on board components are thru-hole (none Surface Mount) for better thermal characteristic and easy handling.

180502_v01 Schematics |  |
180502_v01 PCB Assembly |  |
180502-1_v01 Schematics |  |
180502-1_v01 PCB Assembly |  |
180502-2_v01 Schematics |  |
180502-2_v01 PCB Assembly |  |
180502-3_v01 Schematics |  |
180502-3_v01 PCB Assembly |  |
180502-4_v01 Schematics |  |
180502-4_v01 PCB Assembly |  |
180502-5_v01 Schematics |  |
180502-5_v01 PCB Assembly |  |
180502-6_v01 Schematics |  |
180502-6_v01 PCB Assembly |  |
180502-M1_v01 Schematics |  |

180501 CPU PCB

The 180501 CPU Board design target to a smaller version of EDM expansion console with one Atmega328 Promini Microcontroller module. It also can be used as a generic embedded instrumentation by remapping I/Os and modify the firmware as desire. Board size is 3.6” x 1.74” with matching mounting hole for 1602 I2C LCD display module back to back mounts, and secure to face plate via LCD display mounting holes (same as 180420 with 0.3" extended PCB portion for programming socket and LED mounts).

The built-in I/O interface includes; multiple DS18B20 Temperature interface, 4x DMM ports A0~A3 and a current to voltage conversion via LM358 U3 OPAmp sharing A2, A3 Input, Output use as 2x DCA current measurement on A2, A3 if installed. PWM output driver with IR2101 provides both Hi-side and Hi-side driving capability. Two PC817 also equipped for cross platform communication as needs. The minimum operating voltage should be +3VDC about the installed 1st stage voltage regulator, which is +12VDC for 7809 or +15VDC for 7812.

On Promini extend 10pin header, A5, A4, VCC, GND configure to be I2C port for cross module communication and LCD display driver. A7 as PWM Duty adjustment 0-5V input via 5K POT and A6 as PWM Frequency adjustment 0-5V input via 5K POT.

The PCB allows trim-to-fit as needs for smaller footprint and less functions. All on board components are thru-hole (none Surface Mount) for better thermal characteristic and easy handling.

180501_v01 Schematics |  |
180501_v01 PCB Assembly |  |
180501-N_v01 Schematics |  |
180501-N_v01 PCB Assembly |  |

180420 CPU PCB

The 180420 CPU Board design target to a smaller version of EDM expansion console with one Atmega328 Promini Microcontroller module. It also can be used as a generic embedded instrumentation by remapping I/Os and modify the firmware as desire. Board size is 3.6” x 1.44” with matching mounting hole for 1602 I2C LCD display module back to back mounts, and secure to face plate via LCD display mounting holes.

The built-in I/O interface includes; multiple DS18B20 Temperature interface, 4x DMM ports A0~A3 and a current to voltage conversion via LM358 U3 OPAmp sharing A2, A3 Input, Output use as 2x DCA current measurement on A23, A3 if installed. Source VIN+ PWM output with IRF9640 Q1 P-CH MOSFET, Active Low VIN+ pull-up PWM output via Q2 2N7000 N-CH MOSFET, Opto-isolated PWM output via U4 PC817, Frequency Counter input and Two PC817 also equipped for cross platform communication as needs. The minimum operating voltage should be +3VDC about the installed 1st stage voltage regulator, which is +12VDC for 7809 or +15VDC for 7812.

On Promini extend 10pin header, A5, A4, VCC, GND configure to be I2C port for cross module communication and LCD display driver. A7 as PWM Duty adjustment 0-5V input via 5K POT and A6 as PWM Frequency adjustment 0-5V input via 5K POT. Range Adjusment on JP8.

The PCB allows trim-to-fit as needs for smaller footprint and less functions. All on board components are thru-hole (none Surface Mount) for better thermal characteristic and easy handling.

180420_v01 Schematics |  |
180420_v01 PCB Assembly |  |
180420-N_v01 Schematics |  |
180420-N_v01 PCB Assembly |  |

180325 CPU PCB

The 180325 CPU Board design target to EDM main console. It has two Atmega328 Promini Microcontroller module (mini1, mini2 CPU), and two 2004A I2C LCD Display. One CPU for PWM Pulse Generator, DMM functions and Temperature readout, and the second CPU handling all Z-axis, EDM status and controls. Board size is 3.9” x 4.9” with matching mounting hole for dual 2004A I2C LCD display module back to back mounts, and secure to face plate via LCD display mounting holes. 7x LED indicators and both FT232RL 6-pins interface programing socket footprint located at the middle of both display allows external accessible thru front panel cut-outs.

The built-in I/O interface on mini1 CPU includes; Multiple DS18B20 Temperature interface, 4x DMM ports A0~A3 and a current to voltage conversion via LM358 U5 OP-Amp sharing A2, A3 Input, Output use as 2x DCA current measurement on A2, A3 if installed. PWM output driver with mode select, I2C port A5, A4, VCC, GND for LCD and cross platform communication as needs. Default configuration are; D2 Temperature Sensing Data, A0 Main Power Supply input voltage, A1 EDM Probe voltage, A2 Discharge Current, PWM adjustment via 5K POT on A3 Presale, A6 Duty, A7 Frequency, D4 PWM Mode Switch, PWM Output control gate D5, D6, D7, Controls key input D5 Page, D8 Z-DN, D9 Z-UP, D7 RUN D6 STOP and Hard Reset Switch.

The built-in I/O interface on mini2 CPU includes; TB6560 Stepping Motor Driver interface, Motor Speed adjust Potentiometer interface, Eroding Probe and Discharge Current sensing voltage comparators, Sensitivity Potentiometer interface, 3x IR2110 provides 3x Hi-side and 3x Lo-side EDM PWM MOSFET drivers.

Two stage voltage regulation was used for control logic section. Operating voltage is +15VDC typical, +20VDC max (per IR2110 spec). A bread boarding area also configured for 3x vertical mounts LM2596 3A Switch Power modules and re-distributed multiple 2-pin 15V VCC headers.

The PCB allows trim-to-fit as needs for smaller footprint and less functions. All on board components are thru-hole (none Surface Mount) for better thermal characteristic and easy handling.

180325_v01 Schematics |  |
180325_v01 PCB Assembly |  |
180325-1_v01 Schematics |  |
180325-1_v01 PCB Assembly |  |
180325-3_v01 Schematics |  |
180325-3_v01 PCB Assembly |  |

180323 CPU PCB

The 180323 CPU Board design target to highly re-configurable embedded multi-instrumentation with one Atmega328 Promini Microcontroller module. Board size is 3.2” x 1.44” exact match with 1602 I2C LCD display module size and mounts which can be back-to-back mounts and secure to face plate via LCD display mounting holes.

The built-in I/O interface includes; multiple DS18B20 Temperature interface, 4x DMM ports A0~A3 and a current to voltage conversion via LM358 U3 OPAmp sharing A2, A3 Input, Output use as 2x DCA current measurement on A2, A3 if installed. PWM output, Counter Input, and two PC817 equipped for cross platform communication as needs.

The minimum operating voltage should be +3VDC about the installed 1st stage voltage regulator, which is +12VDC for 7809 or +15VDC for 7812.

180323_v01 Schematics |  |
180323_v01 PCB Assembly |  |
180323-1_v01 Schematics |  |
180323-1_v01 PCB Assembly |  |
180323-2_v01 Schematics |  |
180323-2_v01 PCB Assembly |  |
180323-3_v01 Schematics |  |
180323-3_v01 PCB Assembly |  |
180323-N_v01 Schematics |  |
180323-N_v01 PCB Assembly |  |

180322 PB Power PCB

The 180322 PB Power Board provides 15A current limited PWM current output of EDM power by design. The board size is 4.3" x 1.5", and mounting support by 4x on board power devices (1x TO247 MOSFET Q1 and 3x TO220 Schottky Diode D1, D2, D3) attach on to heatsink securely mounts. Thermal Pad and Isolation Bushing are require for power device(s) equipped with exploded metal tab on the body (Same mounting method as all previous PB Power board designs). On board Fuse is 5mm x 20mm 15A and all power connector is 3.5mm Mini Bullet Sockets in gold finish.

The primary Hi-side driver required isolated (floating) 12VDC 1A Power Supply on JP1, and 12Vp-p PWM input signal on JP2 to be operative. Use on board IR2110 to provides Lo-side input capability and cascade output if needed. JP5 floating DMM interface to 180501 CPU board for PWM Pulse current monitoring.

The maximum current on power path is 15A. Install 0.035 Ohms 10W minimum Current sensing resistor across RD1 and RD1, and 5K POT to JP4 to adjust the output’s limited current, or 4.7Kohm 1/4W resistor to set the output current, if POT not in use.

The PCB allows trim-to-fit as needs for smaller footprint and less functions. All on board components are thru-hole (none Surface Mount) for better thermal characteristic and easy handling.

180322_v02 Schematics |  |
180322_v02 PCB Assembly |  |
180322-1_v02 Schematics |  |
180322-1_v02 PCB Assembly |  |
180322-2_v02 Schematics |  |
180322-2_v02 PCB Assembly |  |
180322-3_v02 Schematics |  |
180322-3_v02 PCB Assembly |  |
180322-4_v02 Schematics |  |
180322-4_v02 PCB Assembly |  |

171114 PB Power PCB

The 171114 PB Power Board provides current limited PWM current output of EDM power by design. The board size is 4.87 x 1.5", and mounting support by 6x on board power devices (3x TO247 MOSFET Q1, Q3, Q53 and 3x TO220 Schottky Diode D2, D3, D4) attach on to heatsink securely mounts. Thermal Pad and Isolation Bushing are require for power device(s) equipped with exploded metal tab on the body.

The primary Hi-side driver required isolated (floating) 12VDC 1A Power Supply on JP1, and 12Vp-p PWM input signal on JP2 to be operative.

171114_v01 Schematics |  |
171114_v01a Schematics |  |
171114_v01b Schematics |  |
171114_v01b PCB Assembly |  |

171107 CPU PCB

The 171107 CPU Board design target to EDMP3 main console. It has two Atmega328 Promini Microcontroller module (mini1, mini2 CPU), and two 2004A I2C LCD Display. One CPU PWMGen3 for Pulse Generator, DMM functions and Temperature readout, and the second CPU ZDRV3 handling all Z-axis, EDM status and controls. Board size is 3.9” x 4.87” with matching mounting hole for dual 2004A I2C LCD display module back to back mounts, and secure to face plate via LCD display mounting holes. On-board FT232RL 6-pins interface programing socket and HC-05 Blue Tooth OTA 6-pins interface programing socket for each CPU.

The built-in I/O interface on PWMGen3 mini1 CPU includes; Multiple DS18B20 Temperature interface, 4x DMM ports A0~A3 and a current to voltage conversion via LM358 U5 OP-Amp sharing A2, A3 Input, Output use as 2x DCA current measurement on A2, A3 if installed. PWM output driver with mode select, I2C port A5, A4, VCC, GND for LCD and cross platform communication as needs. Default configuration are; D2 Temperature Sensing Data, A0 Main Power Supply input voltage, A1 EDM Probe voltage, A2 Discharge Current, PWM adjustment via 5K POT on A3 Presale, A6 Duty, A7 Frequency, D4 PWM Mode Switch, PWM Output control gate D5, D6, D7, Controls key input D4 Page-Up D5 Page-Dn, D8 Z-Dn, D9 Z-Up, D7 RUN D6 SET and Soft Reset Switch on D17.

The built-in I/O interface on mini2 CPU includes; TB6560 Stepping Motor Driver interface, Eroding Probe and Discharge Current sensing voltage comparators, Sensitivity Potentiometer interface, 2x IR2110 provides 3x Hi-side and 2x Lo-side EDM PWM MOSFET drivers.

Two stage voltage regulation was used for control logic section. Operating voltage is +15VDC typical, +20VDC max (per IR2110 spec). A bread boarding area also available for addition component siting as needs.

This board could cut along the marked cut-line for other application as needs.

171107_v01 Schematics |  |
171107 PCB Assembly |  |

Lot size of each build is 3-5 pieces.
All item(s) sold at cost to support this project.
Submit your inquiry for details.


Note: All contents subject to change without prior notice.

Update: November 2018

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