G540 (couple of install questions)

[error404]

I got the G540 kit with 3 stepper motors + power-supply and I'm trying wire up.



1-
From the manual:

If your motors are rated below 3.5A you must use a current set resistor across PIN 1 and PIN 5. If your motor is rated at 3.5A or above you can safely not use a current set resistor

Looking at the information in their website the stepper motor that came with the kit seem to be 3.5A, so I am just putting a jumper cable across PIN 1 and PIN5 (wanted to confirm)

2-
PIN 2, 3, and 4 show a ground symbol ? where do I hook them up? The power supply's ground?... (Again, I just wanted to confirm )




3-
The diagram shows an E-Stop... I don't have one yet, can I still use the x2 Mini mill big red button, if I need to stop the machine?
If that is the case, I guess I just need to run a wire from PIN 12 to 10


4-
What is a VDF? is that to control the rpm on the mini mill? (if I had one)

5-
The manual says:

you can plug in your DB25 straight through cable to the G540 and your computer. Use the pinout on page 5 to set up your program’s output pins or load the G540 XML configuration file from the G540 product page on the Geckodrive website.

I found another PDF in the Gecko website with setting for Mach3.. Is this what they are talking about:



6-
The manual says:

The G540 is composed of four individual G250 motor controls, each of which has a trimpot on board to adjust low speed smoothness. In your CNC program set the axis being adjusted to move at 2 revolutions per second and use a non-conductive screwdriver to turn the trimpot in the ADJUST hole on the top of the drive. If you do not have a non-conductive screwdriver you may use a standard screwdriver, but be careful not to touch any components other than the trimpot. The trimpot has 270 degrees of motion and will have an audible “sweet spot” when it is in proper position.

Is it easy to do? I guess when I'm up and running it would make more sense...

thanks!

[doorknob]

1-
From the manual:

Looking at the information in their website the stepper motor that came with the kit seem to be 3.5A, so I am just putting a jumper cable across PIN 1 and PIN5 (wanted to confirm)

You should NOT put a jumper cable across pin 1 and pin 5. That would be like putting a 0-ohm current set resistor across those terminals.

From the Gecko instructions:

Wire your motors to the included DB9 solder cup and secure the backshell connectors. If your motors are rated below 3.5A you must use a current set resistor across PIN 1 and PIN 5. The resistor is calculated by taking the current in amps and multiplying by 1000. If your motor is rated at 2.8A per phase you will have to use a 2.8K 5% 1/4W resistor. If your motor is rated at 3.5A or above you can safely not use a current set resistor; however, your G540 will not go into current standby mode which will result in increased motor heating.

So, you can either leave pins 1 and 5 unconnected, or if you would like your G540 to go into current standby mode when it is inactive (to reduce motor heating), then you should connect a 3.5K resistor across pins 1 and 5.

(Note: 3.5K is not a standard 5% tolerance resistor value. The nearest standard 5% resistor values to 3.5K are either 3.3K or 3.6K. I don't think that it's critical, but you could hand pick one that is closest to 3.5K, or just choose a 3.3K.)

[fragger6662000]

i used two resistors to make 3.5k i think it was 2.5 + 1.0 and don't short the pins together!

[doorknob]

2-
PIN 2, 3, and 4 show a ground symbol ? where do I hook them up? The power supply's ground?... (Again, I just wanted to confirm )

My interpretation of that diagram is that pins 2, 3, and 4 are connected to ground internally within the G540. For the cable that plugs into that connector, those terminals may be connected to the cable's ground shield.

[doorknob]

3-
The diagram shows an E-Stop... I don't have one yet, can I still use the x2 Mini mill big red button, if I need to stop the machine?
If that is the case, I guess I just need to run a wire from PIN 12 to 10

The big red button on the X2 will stop the X2's spindle motor.

It will not stop your stepper motors from turning. Neither Mach3 nor the G540 knows when you have pressed the big red button on the X2. I do not know whether or not the X2 stop button has "spare" terminals that may be used with the G540.

Designing a system-wide E-Stop according to "best practices" takes some study (which I have not done completely yet), and is certainly a good idea to pursue.

[doorknob]

4-
What is a VDF? is that to control the rpm on the mini mill? (if I had one)

A VFD is a "variable frequency drive" which is an accessory unit that some people use to control the spindle speed rpm of certain compatible milling machine motors (which typically are designed for connection to 3-phase AC power).

There has been a lot of discussion on this forum about using the G540's VFD control outputs to replace the function of the X2's speed control potentiometer, however I am not certain whether or not those efforts have been successful. A site search would probably bring up some good discussions.

For starting out, however, you would probably just ignore those terminals.

[doorknob]

5-
The manual says:


I found another PDF in the Gecko website with setting for Mach3.. Is this what they are talking about:

Yes.

[QSPSB]

I highly suggest you get/install an e-stop my friend... I recently converted my mill and run the G540 and have had to hit the oll big red button many of times... It will shut down the G540 and stop the motors on the spot...

But until you do get one.. You can just hit the Esc button on your key board and it will stop the steppers... The G540 will still be on though!!

Below are a few diagrams that may be of some help to you...

Good Luck

[error404]

You should NOT put a jumper cable across pin 1 and pin 5. That would be like putting a 0-ohm current set resistor across those terminals.

From the Gecko instructions:

Wire your motors to the included DB9 solder cup and secure the backshell connectors. If your motors are rated below 3.5A you must use a current set resistor across PIN 1 and PIN 5. The resistor is calculated by taking the current in amps and multiplying by 1000. If your motor is rated at 2.8A per phase you will have to use a 2.8K 5% 1/4W resistor. If your motor is rated at 3.5A or above you can safely not use a current set resistor; however, your G540 will not go into current standby mode which will result in increased motor heating.

So, you can either leave pins 1 and 5 unconnected, or if you would like your G540 to go into current standby mode when it is inactive (to reduce motor heating), then you should connect a 3.5K resistor across pins 1 and 5.

Thank you,
I'm still a little confused when reading that paragraph in the manual.

I'll leave PIN 1 & 5 alone for now (I'll also check what resistors I have around the house... It has been a while since I needed one)

I take that you have a G540 and it is running fine


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[error404]

My interpretation of that diagram is that pins 2, 3, and 4 are connected to ground internally within the G540. For the cable that plugs into that connector, those terminals may be connected to the cable's ground shield.

So, should I leave PINS 2, 3, and 4 alone? No connections at all...


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[error404]

The big red button on the X2 will stop the X2's spindle motor.

It will not stop your stepper motors from turning....

Okay, it sounds important to have one




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[error404]

I highly suggest you get/install an e-stop my friend... I recently converted my mill and run the G540 and have had to hit the oll big red button many of times... It will shut down the G540 and stop the motors on the spot...

But until you do get one.. You can just hit the Esc button on your key board and it will stop the steppers... The G540 will still be on though!!

Below are a few diagrams that may be of some help to you...

Good Luck

Thanks a lot!
As soon as I get home I'll take a look... I think I have download most of the from the gecko website

Man, Is so painful to reply from the phone


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