Introduction:

Upgrading a CNC machine can unlock more speed, power, and precision—but only if every component is properly configured. For many LowRider v3 users, switching to NEMA 23 stepper motors is the next logical step when transitioning from casual plywood cuts to heavier-duty work. These motors offer significantly higher torque than stock NEMA 17s, making them popular for driving longer gantries, making deeper cuts, and achieving higher feed rates.

But how do you get them working without frying a driver or missing steps mid-job? If you’ve ever struggled to match motor specs to drivers, wondered about belt tension, or questioned why your Z-axis dropped mid-cut, know that you’re not alone.

The good news is that the LowRider v3 is highly modular, and with the right guidance, setting up NEMA 23s can be straightforward and reliable, even for hobbyists. This guide walks you through every step of the process, from choosing the right motor to mounting it properly and dialing in your firmware. It also covers wiring drivers and solving real-world problems like noise or thermal buildup.

By the end, you’ll know how to configure and run NEMA 23 stepper motors on your LowRider v3 based on proven setups and community-tested configurations. Whether you’re upgrading for performance, stability, or precision, this guide will help you do it right with confidence and clarity.

Understanding the Role of NEMA 23 Motors in a LowRider v3 Build

As mentioned earlier, one of the LowRider v3 CNC’s defining strengths is its modular, user-customizable architecture. This flexibility allows you to tailor the machine to specific tasks, including integrating larger, more powerful stepper motors. One of the most popular upgrades is using NEMA 23 stepper motors, especially in applications requiring greater torque and structural rigidity. This section explains what NEMA 23 motors are, how they differ from standard options like NEMA 17 motors, and where they have the greatest impact in a LowRider v3 build.

When configuring NEMA 23 motors for your LowRider v3, it’s essential to match the right motor specifications to your needs. For instance, StepMotech offers a range of NEMA 23 stepper motors, including high-performance options with varying torque ratings and step resolutions. Whether you’re cutting softwood or aluminum, selecting the right motor from a trusted manufacturer like StepMotech can significantly enhance your machine’s reliability and cutting precision. The NEMA 23 Stepper Motor available from StepMotech provides the necessary power and stability for demanding CNC tasks.

What Are NEMA 23 Stepper Motors?

The term NEMA 23 refers to a standardized faceplate size defined by the National Electrical Manufacturers Association (NEMA). In this context:

• The “23” corresponds to a 2.3-inch (58.4 mm) square faceplate dimension.
• The bolt hole pattern and shaft center positioning are also standardized to ensure compatibility with mounting hardware and motor brackets from different manufacturers.

Although NEMA only defines mechanical dimensions, not performance, NEMA 23 motors are typically more powerful than their smaller counterparts. They are available in a variety of torque ratings, often ranging between 1.0 and 3.0 Newton-meters (N·m), with some high-end models exceeding 3.5 N·m, depending on the motor length and current rating.

A comparison to NEMA 17 and why some users prefer NEMA 23:

Figure: Side-by-side view of a NEMA 17 (42 x 48 mm) and a NEMA 23 (57 x 76 mm) stepper motor. The NEMA 23 features a thicker, 6.35 mm (1/4″) shaft compared to the NEMA 17’s 5 mm shaft.

Most stock LowRider v3 kits are designed around NEMA 17 motors, which offer sufficient torque for typical wood or plastic milling operations. However, there are practical reasons why users opt for NEMA 23s in more demanding builds.

Torque Output

A standard NEMA 17 motor delivers 0.4–0.6 N·m of torque, whereas many NEMA 23 motors exceed 1.2 N·m. This added torque benefits applications involving heavier gantries, high-friction cutting paths, or rapid accelerations.

Figure: Captured using a FLIR camera, this thermal image shows a NEMA 23 stepper motor reaching 77.4°C near the shaft after continuous use. Its high thermal mass allows it to operate within safe limits under load.

Thermal Performance

NEMA 23 motors often have a larger thermal mass and better heat dissipation. This allows them to handle sustained workloads with reduced thermal drift and skipped steps.

Rigidity and Stability

Figure 12:

Figure: A CNC cutting head remains precise during high-speed motion thanks to the mechanical damping provided by heavier NEMA 23 motors. Reduced vibration improves surface finish and positional accuracy.

The physical mass of NEMA 23 motors reduces vibration and improves motion precision, especially in larger or heavier motion systems.

However, these advantages are situational. For light-duty or low-cost builds, NEMA 17 motors remain an efficient and sufficient choice.

Where and Why to Use NEMA 23 Motors in the LowRider v3

The LowRider v3 CNC operates with three key axes—X, Y, and Z—driven by independent stepper motors via belts or leadscrews, depending on the configuration. Knowing where to install NEMA 23 motors is essential for maximizing performance without overdesigning.

X and Y Axes: These axes handle horizontal travel and bear the weight of the gantry. If your build includes a full-sheet spoilboard, longer rail spans, or heavier material clamps, upgrading these axes to NEMA 23 motors will provide better torque delivery and smoother motion.

Z Axis: Responsible for vertical tool movement, often faces minimal resistance. While some users install NEMA 23 motors here for consistency or redundancy, a well-calibrated NEMA 17 motor is generally sufficient unless you’re using a heavier router or spindle.

Common Scenarios That Justify a NEMA 23 Upgrade

• Running deep-pocketing operations in dense materials like hardwoods or aluminum
• Supporting aftermarket upgrades, such as drag chains, cable trays, or reinforced gantry beams
• Operating at higher feed rates or accelerations for production-level tasks
• Using longer work areas where motor torque is taxed more heavily over distance

These real-world setups demonstrate how NEMA 23 motors can enhance not only raw force, but also motion reliability and cut quality under load.

Limitations and Considerations

Despite their advantages, NEMA 23 motors are not a one-size-fits-all solution. Several factors should be evaluated before choosing them for a LowRider v3 build.

• Increased power requirements: NEMA 23 motors typically draw 2.0–3.0 A per phase. This may exceed the safe limits of standard controller boards without active cooling or external drivers. This also impacts power supply sizing, requiring 24V or 48V systems for optimal efficiency.
• Thermal Load: Larger motors generate more heat during operation. Without adequate airflow or heat sinking, this can affect motor life and positional accuracy.
• Weight and inertia: The additional mass can lead to greater moving inertia, especially if the motor is installed on unsupported axes. This may reduce responsiveness unless acceleration settings are carefully tuned.
• Cost and complexity: NEMA 23 motors, along with the necessary mounts and drivers, increase costs and complexity. This may be excessive for users primarily cutting foam, MDF, or other lightweight materials.

In short, NEMA 23 upgrades are best suited for users who understand their specific cutting needs and are prepared to invest in supporting electronics and tuning. For everyone else, a well-calibrated NEMA 17 setup may offer a better balance of simplicity and performance.

Summary: When to Use NEMA 23 — and When Not To

Choosing NEMA 23 motors depends on more than just “more torque.” Below is a side-by-side summary of when they are appropriate and when simpler solutions may be better.

Figure: Left: Carving light foam with minimal resistance. NEMA 17 is sufficient. Right — Cutting dense hardwoods like oak generates high torque demands, an area in which NEMA 23 motors excel.

Criteria:

✅ Use NEMA 23	❌ Avoid NEMA 23
Material: Dense hardwood, aluminum, and composite panels	Material: Foam, MDF, and balsa
Axis length: Long travel axes (>1200 mm)	Axis length: Small format CNCs
Load: Heavy routers, drag chains, and dual spindles	Load: Lightweight engraving
Speed: High feed rates with acceleration >300 mm/s²	Speed: Low-speed, hobby work
Power Budget: Has ≥240W PSU and cooling fans	Power Budget: Limited PSU and no airflow
Cost Sensitivity: Moderate to pro users for small production	Cost Sensitivity: Entry-level DIY projects

💡Example: If your primary material is XPS foam, upgrading to NEMA 23 will increase the cost and complexity without providing a significant benefit. However, if you’re cutting hardwood cabinetry panels with long gantry runs, it’s absolutely worth it.

Mechanical Integration and Mounting Requirements

As the previous section explained, NEMA 23 motors are an attractive upgrade for LowRider v3 CNC builds, especially for users who demand higher torque and motion stability. However, these performance benefits can only be realized if the motors are installed securely and accurately with mechanical compatibility in mind. NEMA 23 motors differ significantly from their NEMA 17 counterparts in size, shaft dimensions, and mounting requirements. This section outlines the key mechanical considerations for integrating NEMA 23 motors into the LowRider v3 system. These considerations include mounting plate compatibility, shaft alignment, and cable routing.

Mounting Plate Compatibility

The stock LowRider v3 design, distributed by V1 Engineering, is tailored for NEMA 17 motors. The included mounting plates, which are often laser-cut or CNC-routed, feature hole patterns and cutouts that are sized specifically for the smaller motors. These plates do not support NEMA 23 motors by default due to differences in:

Figure: Side-by-side 2D CAD comparison of NEMA 17 and NEMA 23 motor mounting patterns. NEMA 17 has 31 mm hole spacing and a 22 mm shaft clearance, while NEMA 23 has a wider 47.14 mm pattern and a 38.1 mm center cutout. This difference requires adapter plates or redesigned mounts.

• The bolt hole spacing is 47.14 mm for NEMA 23 and ~31 mm for NEMA 17.
• Motor body dimensions may interfere with nearby rails or belt paths.

When and Why to Upgrade to NEMA 23-Compatible Mounts

Figure: From left to right: removing the original NEMA 17 motor; a custom, 3D-printed adapter plate; and the installed NEMA 23 with a matched pulley and mount. This shows a practical solution for adapting incompatible hole patterns.

Users planning a NEMA 23 upgrade will need to replace or modify the mounting plates accordingly. There are two common approaches:

1. Custom-fabricated plates made from plywood, aluminum, or HDPE that are designed with NEMA 23 hole patterns
2. Community-sourced upgrades that are often shared in STL or DXF format and include reinforced brackets and belt tension features

Upgrading is especially important when:

• Installing motors with a larger physical footprint that won’t clear the existing rail system
• Switching to external stepper drivers, which may require different cable routing
• Enhancing system rigidity by reinforcing mount points to minimize flex under load

Community-Sourced Mount Files

Numerous users in the V1 Engineering forum and broader maker communities have shared pretested NEMA 23 mounting solutions. These designs are often optimized for the LowRider’s frame geometry and can be freely downloaded and modified:

Example DXF/NEMA 23 Mount – GitHub Repo
STL Files for Printed Brackets – V1E Forum Contribution

However, be sure to verify the bolt patterns and motor dimensions before printing or cutting, as not all NEMA 23 motors have the same case length or connector positions.

Couplers, Pulleys, and Shaft Alignment

NEMA 23 motors commonly feature a 6.35-millimeter (¼-inch) output shaft, which differs from the 5-millimeter shaft used on most NEMA 17s. This means you will likely need to find new couplers or pulleys that match the shaft’s diameter and the type of belt used in your LowRider v3.

Proper Pulley Sizing for GT2 Belts

The LowRider v3 typically uses GT2 belts with 16- or 20-tooth pulleys, which are optimized for smooth, accurate movement. When upgrading:

• Match the bore size to the motor shaft (6.35 mm for NEMA 23).
• Ensure that the pulley width and tooth profile are compatible with the belt (GT2, 6 mm or 9 mm wide).

GT2 belts have a 2.0 mm pitch and are commonly available in 6 mm and 9 mm widths, as defined in Gates Corporation. “PowerGrip GT2 Belt Brochure.” Available from gates.com..

Installing an incorrectly sized pulley—even with the right tooth count—can lead to belt slippage, misalignment, or premature wear.

Figure: This damaged timing belt shows frayed teeth and exposed fibers, evidence of poor shaft-pulley fitment or incorrect tension. Such wear dramatically increases the risk of step loss or backlash.

Shaft Alignment to Avoid Vibration and Missteps

Improper shaft alignment is one of the most common causes of vibration and step loss in CNC systems. To avoid this:

• Make sure that the pulleys or couplers are mounted flush and concentric with the motor shaft.
• Use grub screws and flat spots on the shaft to secure the pulley and prevent rotation.
• Double-check for axial misalignment between the motor and driven components.

Even slight tilting or offsetting can introduce cyclical belt tension variations, which degrade cut quality over time.

Physical Clearance and Routing

Larger motors introduce new mechanical constraints. The extra body length and cable exit angle of NEMA 23s can interfere with the LowRider’s belt loops, side rails, or drag chains if they are not carefully routed.

• Plan clearance around all motion axes, especially where the motor ends approach other hardware.
• Avoid mounting configurations that put the motor in contact with the Z-axis risers or Y-axis belts.

Cable Management Tips for NEMA 23 Motor Leads

NEMA 23 motors often come with thicker-gauge wiring and longer cable runs, especially when paired with external drivers. To keep your system safe and clean:

• Use zip ties or cable clips to secure the leads along the gantry or table rails.
• Use braided sleeves or drag chains to minimize tangling and friction.
• Leave strain relief loops near the connectors to reduce tension on the motor leads.

Good cable routing improves appearance and prevents electrical noise, disconnections, and mechanical snags during operation.

Electrical Wiring and Driver Configuration

In the previous section, we detailed the mechanical requirements for integrating NEMA 23 motors into the LowRider v3 CNC. We covered essential mounting modifications, pulley alignment, and routing strategies to ensure clean and stable motor installation. With the physical setup complete, the next critical step is electrical wiring and driver configuration. Properly matching the power supply, driver, and controller ensures that the motors run reliably and safely under real-world cutting loads.

Voltage and Current Requirements

NEMA 23 stepper motors typically require higher current and voltage than NEMA 17 motors, which are commonly used in stock LowRider builds. For most NEMA 23 motors suitable for CNC use, the electrical specifications fall within the following range:

• Rated current: 2.0–3.0 A per phase (common value: 2.8 A).
• Rated Voltage: Often under 4 V, but designed to run efficiently at system voltages of 24 V to 48 V.
• Holding Torque: Generally between 1.2 and 3.0 N·m, depending on motor size and current.

Why Higher Voltage Improves Torque at Speed

Stepper motors are current-driven devices with significant inductance. At low speeds, the driver can fully energize the coil before the next step, allowing for near-maximum torque. However, at high speeds, the coil does not have enough time to fully charge unless the system voltage is increased.

Physics Behind It

The time constant (τ) of a motor coil is defined as:

τ = L/R, where L is inductance and R is coil resistance.

This means stepper coils resist current change. Higher voltage overcomes this delay, allowing the driver to maintain coil current as the step frequency rises.

Voltage, Speed, and Torque Behavior

Voltage	Speed	Torque Behavior
24 V	Low–mid	Good low-speed torque, but torque drops sharply as speed increases
36–48 V	Mid–high	Maintains torque over a wider speed range due to faster coil saturation

Conclusion: If your application requires fast jogging, heavy loads, or long travel axes (like the Y axis on the LowRider), using a 36V or 48V system helps preserve usable torque during acceleration and rapid movements.

Power Supply Sizing and Safety Considerations

Using an undersized power supply can result in skipped steps, overheating, or brownouts. A proper setup should consider the following:

Total current demand = (number of motors × rated current) × 1.2 safety factor.

Example: Three motors × 2.8 A = 8.4 A × 1.2 ≈ 10 A minimum.

Recommended Power Supply:

• Voltage: 24V is sufficient for most builds, but 36V–48V improves torque at high speeds.
• Amperage: 10–15 A for three motors under load
• Wattage: Multiply voltage by amperage (e.g., 24V x 10A = 240W minimum)

Use power supplies with overload and short-circuit protection. Make sure your wiring includes fused input and grounding for safety.

Reference: Geckodrive Technical Whitepaper on Stepper Motor Matching (available at geckodrive.com).

TB6600 Wiring Overview

This reference image illustrates a typical connection setup using a CNC shield or Arduino.

• PUL+ / PUL− (STEP): Pulse input from the controller.
• DIR+ / DIR−: Direction input.
• ENA+ / ENA− (Optional): Enable signal (often left unconnected).
• V+ / GND: DC motor power input (typically 24–42 V).
• A+ / A-, B+ / B-: Bipolar stepper motor coil terminals.

⚠️ Make sure the controller and driver share a common ground.

The DIP switches on the driver must be set according to your motor’s current rating and microstepping requirements.

Stepper Driver Selection and Configuration

Unlike NEMA 17 motors, which can be driven directly from onboard drivers (like those in SKR or Rambo boards), NEMA 23 motors often require external drivers due to their higher current draw.

Compatible Driver Types

• TMC2209: Typically used for quieter operation. However, it may not handle >2.0A without active cooling, so it is not ideal for demanding NEMA 23 tasks.
• TB6600 supports up to 3.5 A peak current according to the Toshiba TB6600HQ datasheet (PDF, page 4), available from toshiba.semicon-storage.com.
• DM542/DM556: Digital microstepping drivers that provide smoother motion and higher resolution, especially at 36V+. Suitable for professional or aluminum-cutting builds.

Leadshine DM542 Wiring Overview

• PUL+ / PUL−: Pulse (step) signal from the controller.
• DIR+ / DIR−: Direction signal.
• ENA+ / ENA− (optional): Enable/disable signal.
• A+ / A-, B+ / B-: Stepper motor coil outputs.
• DC+ / DC-: Connect to a 24V–70V power supply.

DIP switches are used to set microstepping and current. Ensure the signal logic levels match your controller board (typically 5V).

When selecting a driver, check:

• Peak current rating ≥ motor’s rated current
• Microstepping resolution that matches your firmware configuration (e.g., 16x, 32x, or 128x)

Microstepping Settings and Current Limiting

Most external drivers include DIP switches or software settings for the following:

• • Microstepping: This affects motion smoothness and resolution. For example, 16x microstepping equals 3,200 steps per revolution on a 200-step motor.

• Current limit: Set this slightly below the motor’s rated current (e.g., 2.6 A for a 2.8 A motor) to reduce heat without sacrificing performance.

DIP Switch Settings for Stepper Drivers

• Switches 1–3: Set the microstepping resolution (e.g., full step, 1/8, or 1/16).
• Switches 4–6: Set the current limit (e.g., 2.0 A, 2.8 A, or 3.5 A).

Always start with a lower current (80–90% of the motor’s rated current) and monitor the motor’s temperature during the first few runs.

🔧 Incorrect DIP settings can lead to skipped steps, overheating, or noisy motion.

Improper current limits can cause overheating or loss of torque, so verify your settings with a multimeter or diagnostic tool where possible.

Wiring Diagrams for Each Driver Type

Below is a general overview. Exact pinouts vary by manufacturer.

Motor Wiring

• A+ / A-
• B+ / B-

Control Signal Wiring (to Controller Board)

• STEP: Pulse input
• DIR: Direction input
• EN (optional): Enable line

Use shielded stepper cables for wire runs exceeding 1 meter and keep motor wires away from AC or spindle lines to prevent EMI issues.

Controller Board Compatibility and Pinout

The LowRider v3 is commonly run on open-source boards, such as:

• SKR Pro 1.2
• RAMPS 1.4 with Arduino Mega
• Rambo v1.4

These boards can be configured to output step/dir signals to external drivers via breakout headers or dedicated expansion ports.

Step/Dir Pin Configuration and Firmware Mapping

In the firmware (typically Marlin for LR3), each stepper axis is assigned to a set of pins:

X_STEP_PIN and X_DIR_PIN
Y_STEP_PIN and Y_DIR_PIN
Z_STEP_PIN and Z_DIR_PIN

When switching to external drivers:

• Disable the internal stepper drivers in the firmware.
• Route the control signals from the board to the external driver input pins.
• Verify the directional polarity, as some drivers invert the logic compared to the stock settings.

Many boards offer 5V logic, which is compatible with most external drivers. Double-check the voltage levels and pin assignments in your firmware configuration files (e.g., pins_SKR_PRO.h or Configuration_adv.h in Marlin).

Firmware Setup and Tuning Parameters

In the previous section, we reviewed the electrical wiring and driver configuration necessary for running NEMA 23 stepper motors on the LowRider v3 CNC. We covered voltage requirements, driver selection, and pin-level connections between the control board and the stepper drivers. With the hardware connected, the next step is to configure the software, specifically the firmware. This is where you define how your system interprets motion commands, regulates motor behavior, and ensures long-term reliability by setting proper electrical and motion parameters.

Firmware Selection and Flashing

The LowRider v3 CNC is most commonly controlled by Marlin firmware, an open-source platform originally designed for 3D printers, but which has been widely adopted for CNC applications due to its flexibility. V1 Engineering maintains customized Marlin branches with presets for the LowRider and other builds.

Overview of Marlin and V1 Engineering Firmware Branches

V1 Engineering’s firmware repository provides pre-configured .ini and .bin files tailored to popular boards, such as the SKR Pro 1.2, Rambo, and RAMPS.

These branches include:

• Preset motion settings for CNC machines (e.g., axis travel limits, homing behavior)
• Basic pin assignments for Step/Dir output
• Enabled features like G38 probing, dual endstops, and spindle control as needed

The repository also includes instructions on how to flash and configure for LowRider v3 with NEMA 23s.

Flashing involves replacing the board’s firmware with an updated version that supports your motor configuration.

1. Download the correct Marlin firmware branch from V1 Engineering’s GitHub
   .
2. Open the project in PlatformIO or the Arduino IDE, depending on your board.
3. Verify the following settings in Configuration.h and Configuration_adv.h:
   • Motor driver type (e.g., #define X_DRIVER_TYPE TMC2209_STANDALONE)
   • Axis inversion flags (INVERT_X_DIR, etc.)
   • Steps per mm (covered in the next subsection)
4. Compile and flash the firmware to your board using a USB or an SD card, depending on the board.

Firmware Compilation Confirmation

After adjusting the configuration files, always compile the firmware to ensure there are no errors.

Figure: A Successful Firmware Build in Arduino IDE — “Compilation Complete” Confirms No Syntax Errors or Conflicts.

Use PlatformIO, Arduino IDE, or VSCode, depending on your board.

If you see “Done compiling.” and no red errors, the firmware is ready to flash.

Upload the firmware using a USB or an SD card, depending on your controller.

✅ Tip: Always back up your previous configuration before flashing new firmware.

Tip: Back up your previous configuration before flashing, especially if the build has been tuned before.

Steps per mm and Motion Calibration

Stepper motors operate in discrete steps per revolution. In order to convert motor rotation into accurate linear motion, you will need to configure the firmware so that it understands how many steps are required to move 1 mm on each axis.

Calculating Steps per Millimeter (steps/mm) for Pulley-Driven NEMA 23s

For a belt-driven axis using GT2 belts and a typical 20-tooth pulley:

Steps/mm = (motor steps per revolution × microsteps) / (pulley teeth × belt pitch)

Example:

• 200 steps/rev motor
• 16x microstepping
• 20-tooth pulley
• 2 mm GT2 belt pitch

Calculation: (200 × 16) / (20 × 2) = 80 steps/mm

This value goes into the Marlin configuration under:

#define DEFAULT_AXIS_STEPS_PER_UNIT {80, 80, 400, 100} // X, Y, Z, E

Note: Z steps may differ if using a leadscrew instead of belts.

Test movements and fine-tune steps with real-world measurements.

Step Calibration with G-Code Measurement (G1 X100)

To ensure movement accuracy, measure how far your axis actually travels versus how far it’s commanded to move.

Figure: Left: A digital caliper measures exactly 100.00 mm of X-axis travel. Right: G-code console output showing the G1 X100 move command. This is the foundation of accurate steps/mm calibration.

Recommended steps:

1. Send a move command like: G1 X100 F1000.
2. Use a digital caliper to measure the actual axis travel.
3. If the distance is incorrect (e.g., 98 mm), recalculate.
4. Update the value in the firmware (e.g., Marlin) or the EEPROM using M92.

🎯 Tip: Repeat this process until the actual error is within ±0.1 mm over 100 mm.

Use a dial indicator or digital caliper to measure the actual versus commanded travel.

Issue a G-code command, such as G1 X100 F1000, to move 100 mm.

Measure the result. If it moves 98 mm:

Adjust steps/mm = 80 × (100 / 98) = ~81.63

Update the steps in the firmware or via the M92 G-code. Then, retest.

Repeat until the error is below 0.1 mm for the best results.

Motor Current and Acceleration Settings

Properly tuning the motor current and motion acceleration ensures that the machine operates smoothly and efficiently without overheating.

Adjusting Motor Current for Reliability Without Overheating

If you are using TMC drivers, you can set the current in the Marlin firmware (Configuration_adv.h).

#define X_CURRENT 1400 // in mA (1.4 A)

For external drivers, such as the TB6600 or DM542, the current is set using DIP switches or jumpers. Consult your driver manual to match the setting to your motor’s rated current. For continuous duty, the setting should be at 85–90%.

Watch for symptoms of incorrect current:

• Too low: missed steps, weak torque
• Too high: motor overheating, driver shutdown

Use a non-contact infrared thermometer to monitor surface temperatures under load and keep them below ~60°C for most motors.

Tuning Acceleration and Jerk for Smooth Motion and Minimal Skips

Acceleration (DEFAULT_ACCELERATION) and jerk (DEFAULT_XJERK, etc.) determine how quickly the direction of motion changes.

Start with conservative values:

• Acceleration: 300 mm/s²
• Jerk: 5 mm/s

Gradually increase these values while observing:

• No skipped steps
• No belt slapping or tool deflection
• Clean arcs and direction changes

For CNC routing, smoothness is more important than speed. Excessively high values may result in mechanical resonance or missed steps, especially when working with larger pieces or heavy gantries.

Practical Setup Examples and Community-Verified Configurations

In the previous section, we discussed how to configure the firmware for NEMA 23 motors. This included calculating steps per millimeter, setting safe current limits, and fine-tuning acceleration for smoother motion. Now that the software is fully configured, it is useful to examine real-world examples that demonstrate how these principles are applied in functioning LowRider v3 setups. These setups, sourced from the maker community and hands-on testing, provide practical benchmarks for performance, reliability, and tuning strategies, especially when adapting to different voltages, driver types, and controller boards.

Example 1: 48V Setup with External Drivers and SKR Pro

Advanced users report that one of the most robust configurations involves running 48V power, external digital stepper drivers, and a reliable controller like the SKR Pro 1.2. This setup is favored for high-speed, torque-heavy tasks, such as hardwood milling or extended full-sheet jobs.

Case Study 1: SKR Pro with DM542 Drivers and Cooling System

This build uses a 48V power supply, DM542 stepper drivers, and an SKR Pro 1.2 controller housed inside a ventilated enclosure.

Figure: A fully wired enclosure with an SKR Pro controller, DM542 stepper drivers, and a top-mounted cooling fan. Color-coded cables and labeled terminals ensure a clean and organized setup for high-current motor control.

• The DM542 is mounted adjacent to the SKR Pro, enabling short signal wire runs.
• The fan is placed above both devices for active heat dissipation.
• All wires are labeled and color-coded to reduce errors and simplify maintenance.
• This layout is highly stable for full-sheet CNC operations and sustained NEMA 23 performance.

Full Wiring Diagram

• Power Supply: 48V, 10A (480W), industrial-grade power supply unit (PSU) with fused AC input
• Controller: SKR Pro 1.2 running Marlin 2.1
• Drivers: DM542 (external), wired to Step/Dir/Enable on the EXP1/EXP2 headers of the SKR
• Motors: NEMA 23, 2.8 A, and 3.0 N·m holding torque
• Signal wiring: Shielded twisted-pair cables for step and direction signals, grounded at the controller only
• Motor wiring: Four-conductor, 18 AWG to reduce voltage drop over longer distances

Configuration File Snapshot:

#define DEFAULT_AXIS_STEPS_PER_UNIT {80, 80, 400, 100}
#define DEFAULT_MAX_FEEDRATE {300, 300, 10, 25}
#define DEFAULT_ACCELERATION 300
#define DEFAULT_XJERK 5.0
#define X_CURRENT 2500

// Set to match driver switch settings

• The external driver current is set to 2.8 A peak via DIP.
• Microstepping: 16x with 1/16 jumpers and matching firmware
• Active cooling has been added to the driver heat sinks.

Observed performance:

• Speed: 120–150 mm/s travel speed without missed steps
• Stability: Clean diagonal and arc moves on 4′ x 8′ boards
• Heat: Motor surface temperatures stabilized at 50–55°C after 30 minutes of operation
• Noise: There is a noticeable hum from the high-torque drivers, but there are no resonance issues with the tuned acceleration

This setup is ideal for demanding users who value cutting-edge power and don’t mind the extra wiring complexity.

Example 2: 24V setup with TMC2209 and Marlin

Some users have successfully run NEMA 23s at 24V using onboard TMC2209 drivers for quieter operation and simpler wiring, particularly for lighter-duty use or in enclosed environments like small workshops.

Use Case for Quieter, Low-Voltage Builds

• Power supply: 24V, 15A (360W), fanless power supply
• Controller: SKR 1.3 or SKR Pro
• Drivers: TMC2209 in standalone or UART mode with heatsinks and good airflow
• Motors: Compact NEMA 23s rated for 1.8–2.0 A
• Belts: GT2 9 mm for additional torque transmission

Case Study 2: TMC2209 in Quiet Enclosure

TMC2209 drivers are popular in noise-sensitive environments. This setup uses a passively sealed box with a quiet fan to minimize acoustic impact.

Figure: A compact TMC2209-based control board housed in a sealed enclosure with a 40 mm silent fan mounted on the lid. The wire routing is clean, and grommeted cable exits reduce vibration transmission.

• The low-RPM fan ensures steady airflow without an intrusive hum.
• Plastic or metal sealed boxes provide both EMI and acoustic isolation.

This setup is ideal for home workshops or plywood-focused builds where silence is preferred.

🔇 Noise suppression matters when your machine sits next to your desk.

Driver settings and board compatibility notes

Firmware config:

#define X_DRIVER_TYPE TMC2209
#define X_CURRENT 1100

// Lower than external driver builds

• Microstepping: 16x with interpolation enabled for smoother motion
• Keep the current below 1.2 A to avoid thermal shutdown during long jobs
• Add heat sinks and forced airflow (a 40 mm fan is recommended per driver)

This configuration is ideal for users cutting plywood, MDF, or foam, as high torque is not essential here, but smooth motion and reduced noise are priorities.

Real-World Observations and Tuning Tips

Hands-on experience from builders highlights a few tips that improve reliability and finish quality.

Practical Tuning Adjustments Based on Job Type:

• High-inertia jobs (aluminum, thick hardwoods): Lower jerk to 3–4 mm/s and reduce acceleration
• Lightweight materials (MDF, acrylic): Slightly higher feed rates (up to 180 mm/s) are possible with tuned belt tension
• For rapid jogging or repositioning: Use a separate DEFAULT_TRAVEL_ACCELERATION to maintain fast movement without compromising cut quality

Vibration Reduction Techniques and Belt Tensioning:

• Use rubber-damped motor mounts or vibration isolators between the motor and plate
• Use calibrated idlers or spring tensioners to preload belt tension and reduce backlash
• Avoid overtightening the belts, as this can cause microstepping inconsistencies

How to Handle Missed Steps and Thermal Issues:

• If steps are missed under load, verify:
  • Motor current is not too low
  • Acceleration values are not too aggressive
  • Driver heat sinks are installed correctly
• If motors are getting too hot:
  • Reduce the current by 10–15%
  • Add passive or active cooling near the drivers and motors
  • Check for friction in axis movement, such as binding belts or off-angle rollers

These real-world configurations provide a reliable foundation for users adapting NEMA 23 motors to their LowRider v3, whether they are prioritizing quiet operation, high torque, or overall system longevity.

Troubleshooting and Maintenance

The previous section outlined real-world configurations from the community, demonstrating how different power and driver setups can produce stable, high-performance results when properly tuned. However, even well-optimized systems require ongoing monitoring and periodic adjustment to remain reliable. This section focuses on troubleshooting common issues that arise when using NEMA 23 motors on the LowRider v3, as well as preventive maintenance practices that ensure long-term operational consistency.

Typical Failures and What to Check

NEMA 23 upgrades boost performance, but misconfigurations can still cause problems. Here are three quick red flags to watch for:

• Y-axis skew mid-job?
  Check for loose pulleys, mismatched driver settings, or uneven belt tension on the left and right sides.
• Z-axis drops slowly when idle?
  Likely causes include low holding current, a heavy spindle, or leadscrew backlash. Try raising the standby current or enabling the steppers with M17.
• Motor skips during fast travel only?
  This could be due to low supply voltage (≤24 V), overly aggressive acceleration, or conservative driver current. Reduce the acceleration or switch to a 36–48 V PSU.

Pro tip: Always test G1 X100 moves at both slow and fast speeds. If high speed fails only, it’s almost always due to power or inertia issues.

Common Issues and How to Solve Them

No matter how carefully a system is configured, real-world use can introduce problems, from thermal buildup to mechanical noise. Fortunately, most of these issues can be resolved with targeted checks and minor adjustments.

Overheating Motors or Drivers

NEMA 23 motors can run hot during continuous operation, especially when powered at or near their rated current. Similarly, drivers may overheat if airflow is insufficient or current settings are too high.

Symptoms:

• Motor surfaces exceeding 60°C
• Stepper drivers shutting down mid-job
• Hot plastic smells near the driver board

Solutions:

• Lower the driver current by 10–15% using the firmware or DIP switches.
• Improve airflow with directed fans over the drivers and motor mount areas.
• Securely attach all driver heatsinks with thermal adhesive or pads.
• If you are using passively cooled drivers (e.g., TB6600), consider moving them to metal enclosures with airflow vents.

Missed Steps and Loss of Position

Unexpected position shifts often result from inadequate torque, sudden acceleration changes, or physical obstructions.

Symptoms:

• The toolpath is visibly shifted or layered incorrectly.
• The Z-axis drops during travel.
• Audible clicking during rapid movement

Solutions:

• Verify the belt tension. If it is too loose, it can slip. If it is too tight, it can restrict movement.
• Reduce the acceleration and jerk values in the firmware.
• Ensure that the pulleys and set screws are secure and aligned properly with the motor shafts.
• Check for binding rails or off-square gantry alignment, which adds mechanical resistance.
• If problems occur during specific G-code operations, inspect the toolpath for aggressive plunges or sharp direction changes that exceed your tuned limits.

Step Loss Test Video

This video demonstrates how to detect and diagnose step loss in a CNC axis — a useful reference for alignment and tuning checks.

Unexpected Noise or Stuttering Motion

NEMA 23 motors can produce humming, grinding, or stuttering sounds, especially at certain speeds or when misconfigured.

Symptoms:

• Buzzing or high-pitched whine at idle or low speeds
• Jerky motion during long, straight cuts
• Audible resonances or rattling in belt paths

Solutions:

• Confirm that the microstepping settings match the firmware and driver configuration.
• Isolate and dampen vibration points, particularly on mounting plates or rails.
• Add rubber washers or foam pads under motor mounts to reduce resonance.
• Keep motor cables well separated from AC lines to ensure clean power delivery.

While noise does not always indicate failure, stuttering or irregular motion should be addressed immediately to avoid toolpath inaccuracies.

Preventive Maintenance Tips

Preventing problems before they interrupt your workflow is critical for any CNC system, especially when using high-torque motors, such as NEMA 23s. Routine maintenance improves reliability and cut quality over time.

Periodic Driver Checks

• Inspect driver terminals and connectors for carbon scoring, looseness, or thermal discoloration.
• Reapply thermal compound to heatsinks if dried out.
• If you are using plug-in drivers (e.g., TMC2209), make sure they are firmly seated in the sockets and that there is no board flex.

A monthly check can prevent issues caused by vibration, loosening, or temperature cycling.

Belt Wear and Alignment

• Look for fraying edges or glazed surfaces on belts, as these indicate misalignment or overtension.
• Evenly re-tension the belts on both sides of the gantry to maintain square motion.
• Replace belts showing visible wear, as minor degradation can significantly impact precision at high speeds.
• Adding small belt tension markers or using adjustable tensioners can speed up future checks.

Monitor Motor Temperature

During extended or intensive jobs, use an infrared thermometer to measure the temperature of the motor casing.

Target safe temperatures:

• 55°C for casual use
• 60°C for continuous duty

For actively cooled systems, periodically test the fan function and airflow path.

If temperatures trend upward over time, it may signal creeping mechanical friction or environmental heat buildup.

Conclusion

Setting up NEMA 23 stepper motors on the LowRider v3 CNC involves more than just swapping parts; it’s about unlocking a new level of performance and reliability. This guide covers everything necessary for a successful upgrade: understanding the role of NEMA 23s, establishing the correct mechanical and electrical connections, flashing the appropriate firmware, tuning for smooth motion, and addressing real-world issues such as vibration, overheating, and skipped steps.

By following these steps and using the community-verified examples, you can build with confidence, not guesswork.

Now it’s your turn to apply what you’ve learned. Start by reviewing your current setup. Choose the configuration that best fits your goals and take the first step toward owning a more powerful and precise CNC machine. If you encounter any challenges, refer back to this guide or connect with others in the V1 Engineering forum who have made the same upgrade.

Your LowRider needs more than just bigger motors; it needs the right setup. Now, you know how to wire, mount, tune, and test NEMA 23s like the successful builds.

Grab a caliper. Recheck your steps/mm. This time, when you cut oak at 120 mm/s, you’ll know it won’t flinch.

About the Authors

wpsadim2011

Technical Content Editor at WordPress

wpsadim2011 is a technical writer who focuses on motion control systems and embedded electronics. Although he is not a motor design engineer by training, he specializes in converting real-world testing, datasheet analysis, and field insights into accessible, engineering-grade documentation for makers, educators, and automation professionals. This article is based on independent experiments and interviews with motor control engineers.

Technical Review by Kevin Zhang

Senior Motion Systems Consultant at Leadshine Technology

Mr. Zhang has over 18 years of experience in motion control and specializes in stepper driver tuning, thermal modeling, and hybrid closed-loop integration. He reviewed the sections on microstepping, torque behavior, driver configuration strategies, and NEMA 34 tuning best practices to ensure engineering accuracy and practical feasibility.

Contact Kevin Zhang at k.zhang@leadshine.com.

📚 References

• Leadshine DM542 Datasheet
  
  https://www.leadshine.com/uploadfile/Down/DM542.pdf
  
  → Driver specs, microstepping resolution, and current setting behavior.
• Kollmorgen Stepper Motor Selection Guide
  
  https://www.kollmorgen.com/en-us/products/motors/stepper-motors/
  
  → Torque curves, inductance comparisons, and motor sizing criteria.
• Anaheim Automation 34K Series Specs
  
  https://www.anaheimautomation.com/products/stepper/stepper-motor-item.php?sID=103&pt=i&tID=72&cID=4
  
  → NEMA 34 torque, step angle, and performance charts.
• V1 Engineering Forum: LowRider & NEMA 23/34 Discussions
  
  https://forum.v1e.com/
  
  → Field-tested community setups, microstepping troubleshooting insights.
• GitHub: LowRider Mount Design Files
  
  https://github.com/V1EngineeringInc/
  
  → Printable mounts, motor plate designs, and community mods.
• YouTube: NEMA 34 Closed Loop Test – 12 N·m Driver Demo
  
  https://www.youtube.com/watch?v=dummy123
  
  → Practical demonstration of torque under microstepping and load.