Upgrade 6040 to Gecko G540, what else do I need?

[vosser]

Hi!
I'm planning on buying the G540 4-Axis Digital Step Drive for my CNCEst 6040 as I'm told this is pretty much the best controller I can get for a reasonable amount and it will make a huge improvement.

I have a few questions about this and hope someone can shed some light on what I need.

• The power supply in the original controller is Input 220VAC Output 24V / 6.5A, I've read that I should go for a 48 Volt supply. If so, which should I buy?

• I have different connectors on my motors than the serial looking cable the Gecko drive uses, are these drives compatible?.

• I have read in several places that I can connect the Spindle VFD to the gecko and control it through Mach3, but I have not found any guides on how to do this either, are there any (I asked this question directly to Geckodrive but they did not respond)?

• I have yet to find any guide on how to remove the current controller parts and install the Gecko instead are there any such videos or guides?

• Is there anything I have not mentioned above which I should know or get, this is my first CNC so I might be missing something obvious here.

I've included some pictures which might help fill in more details.
Thank you very much for any help!

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[vosser]

Hey.
Since no one has answered I'm wondering if these questions are to broad to answer or if I am asking them incorrectly.
Would really like some help to continue with my build.

Thank you.

[ger21]

This power supply should work fine.
https://www.automationtechnologiesin...50-48-48v7-3a/
If you intend to switch to higher current motors, this might be a better choice.
https://www.automationtechnologiesin...pply/48v12-5a/

It looks like those are 4 wire motors, so yes, they would be compatible. You just need to solder on the DB9 connectors, and proper resistors. Do you know the specs of the steppers?

The G540 manual shows how to connect the VFD, you'll need to know what all the wires on your VFD are. You'll need an external relay to start and stop the spindle, which should be the wires labeled FWD and the one to the left of it, which I can't read. Is it DCM? It's likely the ground wire for the FWD terminal.

The G540 sends an analog 0-10V signal to the VFD, so you need to know which ones those are. Probably the plug next to the ribbon cable? IF you can't figure it out, it may be easier to just buy a Huanyang FVD for $120
https://www.ebay.com/itm/1-5KW-220V-...5.c10#viTabs_0

I'm not sure if anyone has documented a conversion like this. I don't pay too much attention to any threads on these cheap machines.

[machinejack]

You can run at 24V but is better at higher voltage. You wire directly to the 540's terminal board. The 540 can control the VFD, check the documentation it is good and the folks at Gecko Drive are very helpful. They want you to be happy with your purchase. Go look at there support forum and read others fails and triumphs. All depends on how your VFD connects. I have Mitsubishi VFD been running Gecko's for years thou not the 540 I did help a good friend set up one. I use G 201's my though's are if I fry a single drive which I have done the cost of replacement is less. Plus I keep a spare sitting in the cabinet. I run a Bridgeport Boss 5 with upgraded NEMA 35 motors at 75V. It will plow it's way thru most anything, but am limited by the 2HP on the mill's spindle. Running a small mill I would use the power supply you have and if you have problems you can up grade. Read everything you can find there is lots of info out there.
Have fun double check your wiring and don't let the smoke out. Check with Maurice at Gecko he has answered all my questions.
Jack

[ger21]

I use G 201's my though's are if I fry a single drive which I have done the cost of replacement is less.

Actually, the drives in the G540 are replaceable (G250's), and even cheaper.

And I think you mean Marcus?

[machinejack]

Yea been awhile since I have needed help.