Step 1: Label each Motor cable, Sensor Cable and Extension Cable

Grab All of the Motors, sensors and cables and label near the connectors with their Motor Number or Sensor Number.

There are lots of ways to label the wires here are just some ideas:

• Use a wire label maker, half inch tape with 14pt font (As seen in the image)
• Grab any type of tape wrap it around the wire and write the cable name in
• Find either paint or a colored sharpie add dots, rings, or some symbol on the wire that you are able to identify later on

Step 2: Wire STB4100 To Motor Drivers

Wire all 4 DM542T or TB6600 stepper drivers Pulse and Direction pins

The STB4100 motion card has 4 sets of driver terminals labeled X, Y, Z, and A hook up the drives as follows:

• X → M1
• Y → M2
• Z → M3
• A → M4

Then wire the Driver as Follows:

• XD → DIR-
• XP → PUL-
• +5v should be connected to PUL+ DIR+ and ENA+ (enabled + is optional)

Step 3: Wire Motor Drivers To Power Supply

Wire all 4 stepper Motor Drivers to the 24v 10a Power Supply.

Step 4: Wire NEMA 23 Motor Extension Cables to Motor Drives

Wire Motors M1, M2, M3 Using this color scheme:

• A+ → Black
• A- → Blue
• B+ → Red
• B- → Green

Step 5: Wire NEMA 17 Motor Extension Cables to Motor Drives

Wire the M4 Motor using this color scheme:

• A+ → Red
• A- → Blue
• B+ → Black
• B- → Green

Step 6: Wire Power and Signal from Sensor Extension Cables

Wire the Sensor Cables to the power supply and the Motion Controller

The Sensors should be wired as follows to the Motion Controller:

• White → -V COM
• Yellow → +V 24v
• Black → Input

• S1 → IN1
• S2 → IN2
• S3 → IN3

Step 7: Wire 24v Power To STB4100 Motion Card

The STB4100 card needs +V and -V from the 24v power supply to allow for the inputs and outputs to function.

The STB4100 should be wired as followed:

• STB4100 +V → Power Supply +V 24v
• STB4100 -V → Power Supply -V COM
• STB4100 COM → Power Supply -V COM

Step 8: Wire AC Voltage to Power Supply

Mains voltage is dangerous and can cause serious injury or death if handled incorrectly. Always ensure the power supply is fully unplugged before making any wiring connections. If you are not confident working with mains voltage, consult a qualified adult.

Strip and connect the three wires as follows:

• L (Live) — Brown wire
• N (Neutral) — Blue wire
• GND (Ground) — Green or Yellow wire

These plugs can sometimes come in different colors, these are some other common color schemes:

• L (Live) — Black wire
• N (Neutral) — White wire
• GND (Ground) — Green or Yellow wire

Step 9: Connect Robot To Controller

Connect all of the sensor and motor cables to the controller connectors using the labels we added in the beginning. This is the cable routing I chose, you don’t need it to look perfect, the primary goal here is to prevent the motor cables from snagging or rubbing on any moving parts like belts or moving joints.