MASSO Documentation

 
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Best practice when wiring MASSO

This document outlines recommended work practices when setting up and wiring your MASSO controller.


If you are unsure about any wiring—especially mains voltage equipment—always consult a licensed electrical technician.

 

Install a Fuse

 

WARNING: A 1 amp fuse must be installed between the power supply and MASSO. This fuse is required to protect the controller from accidental short circuits on the auxiliary power connectors. Failure to install this fuse may result in permanent damage to the controller.

 

 

 

 

General Wiring Practices

 

When connecting, disconnecting, or making wiring changes to MASSO, the mains power must be switched off. This ensures that accidental contact with a connection point during installation does not immediately damage the system.

 

After completing any wiring changes, all connections should be carefully checked before restoring power to confirm the system has been wired correctly.

 

Wiring should be carried out in a tradesman-like manner, with wires kept neat and securely captured within the screw terminals. Stray wire strands that are not properly secured can contact adjacent terminals and cause damage. Although bootlace ferrules are not required, their use can help keep wiring tidy and reduce the risk of loose strands.

 

Coloured wiring should be used where possible, and accurate records of all wiring connections between MASSO and external devices should be kept. This will greatly assist with troubleshooting if an issue occurs at a later time.

 

Auxiliary Power Terminals

 

The auxiliary power terminals on MASSO G3 are the red and black terminals labelled POWER and GND. These terminals are intended to provide logic-level power only and should be used exclusively for low-power devices.

 

If there is any uncertainty about whether to use the auxiliary power terminals or the positive and negative terminals of the DC power supply distribution point, the DC power supply distribution point should always be used, as this is the safest option.

 

A suitable application for the red auxiliary power terminal is supplying pull-up resistors for input signals. These resistors should be protected from accidental contact with other circuits. Using clear heat-shrink tubing is recommended, as it allows the resistor to remain visible while providing effective insulation.

 

 

Emergency Stop (E-Stop)

 

WARNING: Emergency Stop wiring must be implemented in accordance with the safety regulations applicable in your country or region. When an E-Stop is pressed, MASSO will place the machine into feed hold and stop the spindle; however, all drives and actuators must be disabled directly by the E-Stop circuit. The E-Stop input on MASSO is designed only to indicate that an E-Stop has been activated and must not be relied upon as a primary safety disconnect.

 

 

An E-Stop output labelled ES is provided on MASSO and may be used to drive a TTL relay module. This output allows external equipment such as drives, spindles, and other actuators to be disabled when an E-Stop is activated.

 

 

 

 

 

CAUTION: Any wiring diagrams provided are for demonstration purposes only and are intended to illustrate the general concept. You must refer to the documentation supplied by your stepper drive, servo drive, and VFD manufacturers to determine the correct and approved wiring methods.

 

INFORMATION: Up to two MASSO relay inputs can be connected to the ES output. If additional relay contacts are required, a TTL relay may be used to drive a relay with multiple contacts, or multiple MASSO TTL relays may be wired as described in the E-Stop wiring documentation: EStop Wiring

 

INFORMATION: Relays controlled by the E-Stop output will be energised when the E-Stop is released and will de-energise when the E-Stop is engaged.

 

INFORMATION: On MASSO G2, Relay Output 7 is assigned as the E-Stop output.

VFD Wiring

 

WARNING: Extreme care must be taken when installing and configuring a VFD and spindle, as these devices operate at high voltages and can cause serious injury or death if handled incorrectly. If there is any uncertainty during installation, a suitably qualified electrical technician must be consulted. VFDs are complex devices, and incorrect wiring or configuration can result in damage to both the VFD and the spindle.

 

The VFD must always be fully powered down before any wiring changes are made.

 

Plasma Wiring

 

WARNING: Plasma systems operate at high voltages and generate significant electrical noise, which can result in serious injury or equipment damage if not installed correctly. Plasma equipment must be installed by a suitably qualified technician, and incorrect wiring can cause damage to MASSO.

 

 

Proper earthing is critical to the correct operation of a plasma machine. Correct earthing allows the arc to function as intended, improves cut quality, and reduces electrical noise that may interfere with THC operation and MASSO performance. The plasma system must be earthed in accordance with the manufacturer’s instructions and established best practices.

 

Control of External Mains-Powered Devices

 

WARNING: All wiring associated with mains-powered devices must be installed by a licensed electrical technician and must comply with the electrical regulations applicable in your country or region.

 

 

Although the MASSO relay module is rated for 240 V at 5 A, it is not recommended to mix low-voltage and mains-voltage circuits on the same relay module. A safer and more robust approach is to use MASSO relay outputs to operate separate mains-rated relays that are installed elsewhere within the control cabinet. All mains relays should be grouped together and adequately shielded to prevent accidental contact.

 

 

 

 

Last Updated On 22 January, 2026

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