Thread: G540Kit + VFD Build help needed

Originally Posted by BoomerangInfo

Hmm, well, I think I have every adaptor available from 5V - 12V, and even one 20V 2A, but nothing 24V

Back to ebay again, and shopping in China () but would either of these work?

24V 4A 96W AC Adapter Power Supply + AU Plug for Laptop Strip RGB LED | eBay

Universal AC Adapter 12V/15V/16V/18V/19V/20V/24V 96W | eBay

I think that'd be cheaper than fuel trying to get to your place Peter, unfortunately.

*EDIT*

And then one of these to replace the round 2-pin plug on my pump cable?

5PCS 5.5x2.1mm Female DC AC Power Plug Connector Adapter For Survey CCTV Camera | eBay

*EDIT #2*

Am I going about it wrong trying to power my current pump? Would it be cheaper/easier to buy a replacement pump? Any recommendations if so?

Being a dc motor, just power the pump off the 20V power supply you have. It will run a little slower but most probably be fine.

Cheers,

Peter

Originally Posted by phomann

Yes, the bootlace ferrules are used for the G540 terminal block.

As to the quick connect terminals, they are use for the power socket, Power supply, relays ,etc

The Power socket in the kit uses the 6.3 spade ones.
Female Spade - Red - Pk.8 - Jaycar Electronics

The repays use the 6.3 and the 4.8mm ones
Mini Female Spade - Red - Pk.8 - Jaycar Electronics

The 48V linear sipply uses these fork ones;
Forked Spade - Red - Pk.8 - Jaycar Electronics

The VFD probably uses the fork ones as well.

OK. Can I get away with one of these crimpers though? Not sure I want to spend $40 - $80 on crimpers I may use only occassionally.

5 Way Crimping Tool - Jaycar Electronics

whats wrong with the power supply from the china box , 40volt , 20 volt , 5 volt

Originally Posted by SawDustSniffer

whats wrong with the power supply from the china box , 40volt , 20 volt , 5 volt

I dunno. Maybe nothing, but I'd rather not have something running that has already blown up one motherboard and keeps tripping my RCD, and with other components drawing who knows how much extra power at the same time. The power for that pump is coming from the huge coil inside the box, isn't it? Surely that's not going to be efficiently running just to power the water pump? I'm just guessing here.

Originally Posted by BoomerangInfo

OK. Can I get away with one of these crimpers though? Not sure I want to spend $40 - $80 on crimpers I may use only occassionally.

5 Way Crimping Tool - Jaycar Electronics

Yes, you can use those. The Ratchet crimper provide a constant force and are easier to use.

Attached is an image of a controller that I recently wired.

Cheers,

Peter.

I'd be getting a power supply from Peter..

PS-01 MeanWell 48Vdc 7.3A Switch Mode Power Supply [PS-01] - US$67.00 : Homann Designs!, The preferred CNC Component Supplier

Last thing you need is a failing power supply when it's plugged into your $270 Gecko.

I purchased one of these

24V 4A 96W AC Adapter Power Supply + AU Plug for Laptop Strip RGB LED | eBay

to power a 24V 2.5A motor and it gave out a modulating voltage.. so I sent it back and they sent another... exact same thing happened. I ended up buying an old 24V CIG transformer for $15 that turned out to be AC not DC as the lady selling it on ebay suggusted so had to convert it. I've no idea what a modulating voltage would do to a Gecko and I've no intention of finding out... just get yourself a proven power supply.

Brad.

Originally Posted by phomann

Yes, you can use those. The Ratchet crimper provide a constant force and are easier to use.

Attached is an image of a controller that I recently wired.

Cheers,

Peter.

Thanks for the picture. So is there any soldering there, or is everything crimped?

Also, I note you haven't used insulated connectors. Does it matter?

Brad,

The 24V for the water pump is stand-alone. It won't be connected to anything else, except maybe via a relay.

Originally Posted by BoomerangInfo

Thanks for that.

Also, here's a picture of the spec on the stepper motors. Do they need a 3K Ohm current set resistor because it says 3A?

I found this spec resistor. Is this one correct? 3K0ohm 1/2 Watt 1% Metal Film Resistors - Pk.8 - Jaycar Electronics

The Rev. 4 Gecko manual listed on Peter's site says it can be a 1/4W 5% resistor, but older versions I found say from 1/10w - 1/2w, 1% - 5%.

Hi Russell,you are where everyone has been at this juncture. Your list seems about right,I use a Temp controlled Dick Smith soldering iron its about $50 to $70 depending on sales.But a small el cheapo $10 one is OK as well unless you are going to get adventurous and put kits together.
I use a G540,fitting the resistors into the plugs is fiddly but not hard,I live 30 km north of Brisbane,[call in if you are going past I'm 1km off Bruce Hwy]my shed gets hot-like about 50c I have a PC cooling fan in an old Gal tranny box to cool it -never missed a beat!
I'll try to upload a pic of it ,its all SH,and cost nouwt --and looks like it too! I'd suggest you could ,just plug along,take note of the good advice you'll get on this site-I lurked here for a long time.Wire up your 240v safely ,use shielded wires on your steppers,earth only one end of the shield back to your,G540 earth then to common.That's what I do anyway.
I'd toss the water pump,I tried fish tank stuff,most was useless. I use a 240v pump from Queensland Trade Tools,its a spare part out of a small parts washer,so will pump solvent or anything,I use tap water and chuck in some GMH radiator antifreeze [before some one says why? at that shed temp]-its to reduce algae ,that's the theory anyway.The pump is noisy and sounds like its clapped,Doesn't appear demountable but I'd say its probably a shuttle pump like most Holley fuel pumps.
This contraption has 400 hrs on the Mach 3 log so its seems OK for what it is,needless to say I cooked a band new 2.2 Kw spindle in about 10 secs first up!Too hasty mate! I use ordinary 3 phase wire to the spindle BUT not thru the cable chain its suspended form a boom over the machine and its earth goes back to the VFD which is in turn earthed thru its normal cable with a suppressor? These use a separate 3 pin power point to the machine--eventually share a common earth tho', my theory is I didn't want to create a ground loop by earthing the spindle back the the Power supply and electronics in the machine itself,so the VFD is mounted on the wall,it has another device which I will wire up one day to switch it on and off and also control the speed with a pot. ATM I use the key pad to do that,which is OK as I've already replaced all the crap Huwangy buttons,which these devices have dubious record of reliability for.
The pic is testing my El Cheapo tranny from a shop where it was used for running display lights, started as 240ac/12vac I changed it to 240ac/24ac-rectified it to DC,
the result you can see on the DMM the lights in the background are sealed beams with all filaments going hooked up in series for a load.About 12 amps roughly on it ATM. The fan on top is for cooling ,run by PC PSU tapped off for 5v-12v etc for fans and things-including G540-in separate box as mentioned,these come free at any dump!
This is record typing effort for me so I hope it helps some-one, Baz

Originally Posted by BoomerangInfo

I found this spec resistor. Is this one correct? 3K0ohm 1/2 Watt 1% Metal Film Resistors - Pk.8 - Jaycar Electronics

The Rev. 4 Gecko manual listed on Peter's site says it can be a 1/4W 5% resistor, but older versions I found say from 1/10w - 1/2w, 1% - 5%.

The 1/2 Watt resistors are fine its what I use as jaycar doesnt have a large range of the 1/4W resistors.

I believe the only reason for a 1/2W limit is the ability to fit inside the DB9 connectors.

Originally Posted by Ch4iS

The 1/2 Watt resistors are fine its what I use as jaycar doesnt have a large range of the 1/4W resistors.

I believe the only reason for a 1/2W limit is the ability to fit inside the DB9 connectors.

Thanks. I'm still tossing up whether the DB9 with the BoB is worth the extra money. Would certainly make it a lot easier. If you do the pins on their own, should they be heatshrinked?

Originally Posted by BoomerangInfo

Thanks. I'm still tossing up whether the DB9 with the G540 is worth the extra money. Would certainly make it a lot easier. If you do the pins on their own, should they be heatshrinked?

They dont need to be, soldering them in provides adequate clearance.

Originally Posted by BoomerangInfo

OK. Can I get away with one of these crimpers though? Not sure I want to spend $40 - $80 on crimpers I may use only occassionally.

5 Way Crimping Tool - Jaycar Electronics

Ok I looked at one of these in Supercheap Auto today (Best Buy Crimping Tool Kit - 181 Piece - Supercheap Auto Australia) and it looks pretty tinny. I thought the 180 pieces might give me all I need, but it seems it's several size reds & blues in male spades & circles, and some wire joiners. Don't think they match what Peter has said though.

Are these Supercheap type connectors (SCA Electrical Terminals - Ring (Eye), Blue, 8.4mm, 14 Pack - Supercheap Auto Australia) the same as the Jaycar ones, or is there a difference? There are multiple spade & eye sizes available.

*EDIT*

I'm confused trying to find the with to match the terminals on the Jaycar site. I assume it's Hookup wire I need. Their sizes are confusing. The "light duty" wire is 13 x .12mm. what does that mean? That doesn't look like a standard wire gauge specification is it? As to which terminals it fits, well their description of those is, for example, 4.3mm cable entry size, 0.75 - 1mm dia. So which fits which?

FOr an enable switch, will any old switch do? Not sure if I've got something to cannibalise, but if not, how's this one look?

SPST Ultra Mini Rocker Switch - Jaycar Electronics