G540 E-Stop

[kolias]

The good news is that I got a green light on G540 and all looks good. Thank you both, you Al and John for all the good help.

Now for the motor cable I thought it will be a piece of cake but looks like I can’t put it to bed LOL
I don’t know what kind conductor I will get but I have seen them at HD single wires and I guess I will just get one with 600V rating. Why is not the best solution Al ?

Regarding your post 160, I don’t understand what you mean. But if you mean to re configure the VS unit to use 3 con 16g + 2 cond 20g I don’t think it is worth the trouble. I mean I got your 4 cond 16g + I will buy a one cond and all I have to do is solder the ends on both sides and I will have what I got from Sherline.

Perhaps I’m missing something?

[Al_The_Man]

Post #139 explains it.
There are two options.
(1) rewire/extend existing cable with 5 cond 16g.

(2) As you had trouble finding the cable I suggested using 3 (or4) cond 15G to just extend the (2) motor and (1) ground conductor(s) and then use 2 conductor ~20g for the sensor, but in this case the sensor would be wired in series with the relay or circuit that switches the power on to the drive.
This would requires a minor difference to the original circuit.
These are two options, I personally would opt for the second for some of the reasons previously mentioned, but it is your choice.
Remember the sensor is not needed to run the motor, it is only a safety item.
Al.

[kolias]

Now I understand but Al, you know MUCH more than I do and therefore I can’t appreciate the difference between the 2 methods. I know that by re design will allow me to use smaller gage wires for the sensor but I’m hesitant to do so because I will go against the manufacturer.

Now if I knew at least half as much as you Al, I will have gone with the re design

I will take the easy route and use the 4 cond 16g + 1 cond 16g

[Al_The_Man]

I know that by re design will allow me to use smaller gage wires for the sensor but I’m hesitant to do so because I will go against the manufacturer.

Thats Ok I understand.
But they are not a 'Manufacturer' they just put a system together from different components and are subject to the mistakes and foibles of anyone doing this!
Al.

[kolias]

You are right, they are not the manufacturer

I was thinking that I can't do very much until I receive the cable and so if it is not too much of a trouble to send me the drawing you mention earlier and I will study to see if I understand it etc.

But please remember that I don't know how to read electrical drawings well so please use explanations and not symbols

[Al_The_Man]

I will put it together over the next day or so as time permits.
Can you identify the relay you are using to turn the drive on from Mach etc?
Previous drawing posted?
Al.

[kolias]

Although I have installed the two 24VDC relays in my controls enclosure, I do not plan to use them soon. I will operate the drive (Taig spindle) manually for the first few months until I get familiar with the machine and controls.

I dont understand what this relay has to do with the cable but you know better. Anyway the relay is T9AP1D52-54 with 24VDC coil

[kolias]

Hey Al

Last night after 10 minutes of operation the A axis EZ-G540 DB9 connector to G540 started to smoke and I shut down the machine. It turns out that one of the 2 screws holding together the DB9 rubbed the insulation of one wire and sort it out.

I have no confidence on the remaining DB9 connectors and I bought 4 new male DB9 plain connectors to re do the wiring and the following resistors.

3.1K, 1/2W (Black ones) and 3.3K, 1/4W (tiny ones) see attached pic

The G540 manual says for my motors which are 2.8A to use 2.8K, current limiting resistors, 5%, 1/4W.

But the guy at the store knows nothing if these resistors are current limiting neither what the 5% means.

To your opinion, is it ok to use these resistors and which one will be better

[Al_The_Man]

Resistor are inherently current limiting, depending on the value, the 5% refers to the tolerance they are manufactured to.
For example say you wanted 5% and only 10% were available, you would have to buy a small quantity and then measure them to select the ones that were close to, or within 5%.
If you really need 2.8k then use the closest 3.1k.
Al.

[kolias]

Thanks Al

On a DC circuit do you normally connect the on/off switch to the + or - ?

Perhaps it makes no difference ?

[Al_The_Man]

On a circuit where the supply -ve is connected to Earth Ground then you would normally switch the +ve.
If floating supply then it is optional, but the tradition has always been to switch the +ve.
in most case.
Al.

[Al_The_Man]

Can you read in a DWG or DXF file?
Al.

[kolias]

I forget which program opens .DWG files but .DXF will be fine.

My Acad is only V14 so if you send me a .DXF from a later version I dont know if I will be able to see all the details etc.

I also have easy access to MastercamX5

My 1st attempt to solder the DB9 socket did not go that well LOL, guess need more practice

[Al_The_Man]

Try this in PDF
The relay would be ready to use with Mach control with a small Modification.
Al.

[kolias]

Thank you Al for taking the time to make such an easy to understand drawing.

To be able to fully understand what I have to do I will have to open the VS unit and follow your drawing to find out if there are any grey areas.

Right now my main concern is to get the machine going again and I’m working to replace the existing EZ-G540 sockets with the new DB9 I bought today. Not an easy task for me….

Please lets touch this subject again after I get the machine running and I have receive the 20 ft cable

Much appreciated

[kolias]

Just a few questions on your drawing, please see the attached JPG

Item1: What these 2 symbols represent?
Item2: What this symbol represent?
Item3: What is DC – (cant read the rest)
Item4: Never thought that 40g wire exist. Is it easy to find?

[Al_The_Man]

1 is the 24vdc relay coil.
2 is the relay normally open contact
3 is DC-ve or DC negative (Common)
4 is a mistake, the new PDF shows 20g.
Al.

[kolias]

I know on DB9 socket, pins 1-5 are ground and I have to connect the resistor between pins 1 and 5.
Pins 6 – 9 are for the motors. But do I have to connect the shield wire to any pin and if yes which pin?

Back to your .PDF

1. The white and orange cables coming from the motor, I will have to connect them to the +24VDC (white) and -24VDC (orange). Then why you repeat the same cables (white and orange) further to the left on your PDF and you say “tape off”. For me, after I connect the white/orange to 24VDC these 2 cables are gone. Is this correct?

2. The NO relay contact on the incoming 120VAC black cable I will assume this relay exists inside the VS unit. Is this correct?

3. After I do all this changes, I should be able to turn the spindle on/off from the switch on the VS unit plus adjust the speed with the knob on the VS unit. Is this correct?

[Al_The_Man]

Not to +24v and -24, you will blow the supply, if you notice one wire, make it Orange will connect to the Coil, not +24, the other, White will connect to the DC-ve.
I assumed you had and intended setting up a 24v relay for the future control of the KB via Mach, this relay is supplied by you.
Like John showed you in Post #107.
The two lengths of Orange and White are not used in the LH side so they are taped up.
Al.

[kolias]

I understand, to my 24VDC relay, thats ok

And yes in the future I will have the VS control thru Mach3

How about the DB9 ground wire Al from my previous post, do I connect it or not and which pin?