Thread: G540Kit + VFD Build help needed

Originally Posted by SawDustSniffer

a 20 volt ,smooth step , is the way to go , but thats 1/2 the voltage it came from china (38 volt ) , due to my making tesla cannons 10 years ago i know ," the voltage is squared , when working out the joules of electro magnet" , so 1/2 the volts will give you 1/4 of the power ???/ any one , want to correct me ??

yes i under stand the speed of the pulse has a lot to do with the power of the motor , but 1/2 the volts ? whats the max volts these drivers can run on , divide that by 1.4 and you pushing the limit ( back rush volts ) with out a back rush diode ( would be fitted to a gekko )


back rush volts : when a magnetic field collapses it will make -1.4 x the voltage of what made the magnetic field in the coil ( spike voltage )" no free energy here "

As Maniel would say, "¿qué?"

Originally Posted by BoomerangInfo

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.

From memory, everything in the controller is crimped. The only soldering was on the microphone socket for relay 2 output, DB9s for the motors,etc

Yes, insulated connectors on the high voltage connections would be preferable.

Cheers,

Peter.

Originally Posted by BoomerangInfo

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?

If you are going to buy a cheap crimper, then the supercheap kit is probably the one to go for.

As to the connectors, they come in 3 colours, Red, blue, yellow. The colour tells you what wire size they fit.
If you look at the pic I posted recently, you will see that they are all red connectors, except where I doubled up the wire, and for the heavier wire for the 48V to the G540.

The connectors also have a few different end types. For the Power supply, use the Fork type. The rest are spade type from memory.

Cheers,

Peter.

Originally Posted by BoomerangInfo

So for the internal wiring, this should be sufficient? Hook-Up Wire Pack - 2 metres - Jaycar Electronics

Is that suitable for the VFD hookups too, or does that need to be the heavy duty stuff? Red Heavy Duty Hook-up Wire - Jaycar Electronics

Ok well I've ordered a soldering & rework station, the G540 kit, including enclosure, chiller AND the DB9 variable resistor pack. I think I've made enough stuff ups so far that I need to make it as simple as possible.

Can someone confirm whether the wire I've linked to above is appropriate?

Thanks.

The only use I can see for the Hook up wire pack is for the enable terminal wiring.

For the 240V wiring, you could use the heavy duty hookup wire you identified as it is rated at 7.5A. Or, you could use the extra heavy duty 10A rated wire,
Brown Extra Heavy Duty Hook-up Wire - Jaycar Electronics

The G540 can draw up to 7A, so I would go for the extra heavy duty wire for the DC power wires.

I had a number of USA IEC power cords around, so at times I've stripped the wire out of them to do heavy duty wiring.

Cheers,

Peter.

Originally Posted by phomann

For the 240V wiring, you could use the heavy duty hookup wire you identified as it is rated at 7.5A. Or, you could use the extra heavy duty 10A rated wire,
Brown Extra Heavy Duty Hook-up Wire - Jaycar Electronics

The G540 can draw up to 7A, so I would go for the extra heavy duty wire for the DC power wires.

Cool thanks. I'll just get a meter of each colour in heavy and extra heavy. Wish they had more colour choice though so I could identify the different parts of the circuit visually.

Originally Posted by BoomerangInfo

Cool thanks. I'll just get a meter of each colour in heavy and extra heavy. Wish they had more colour choice though so I could identify the different parts of the circuit visually.

Sounds good.

Use Brown for the 240V Mains active, Blue for Mains neutral, Green with yellow stripe for earth.

Use Red for +Vdc and black for -Vdc


If you have trouble remembering that brown is active, just remember that if you touch it you will sh*t yourself

Cheers,

peter.

Originally Posted by phomann

Use Brown for the 240V Mains active, Blue for Mains neutral, Green with yellow stripe for earth.

Use Red for +Vdc and black for -Vdc

They only have black/red/green in heavy duty, and brown/blue in extra heavy, so I'll have to make do. I assume you shouldn't mix gauge sizes on the same section of wiring?

I'm off to Jaycar today to pick up the final bits I need I think, and then I just have to wait for all the mail order stuff to arrive. I'll procrastinate on the pump power supply for a while, and just keep using the box I've got for that, and just try to disconnect everything except for the pump power.

Russell.

Originally Posted by BoomerangInfo

I'll procrastinate on the pump power supply for a while, and just keep using the box I've got for that, and just try to disconnect everything except for the pump power.

Hmmm. Just in case, I was going to get a DC plug to change over the current pump plug to match my DC adaptor. Not sure what I saw the other day, but I can't find the 20V adaptor anymore. I did find a 19V, 1.58A though. It says on it 'L.P.S. - Limited Power Supply. For IT equipment and indoor use only'.

Is this something restrictive within this adaptor that might make it unsuitable?

Also, how do you tell the right connector size? I see 2.1mm and 2.5mm adaptors in the Jaycar catalogue. That's kind of hard to eyeball the different. Does that size refer to the centre pin size?

Originally Posted by BoomerangInfo

Hmmm. Just in case, I was going to get a DC plug to change over the current pump plug to match my DC adaptor. Not sure what I saw the other day, but I can't find the 20V adaptor anymore. I did find a 19V, 1.58A though. It says on it 'L.P.S. - Limited Power Supply. For IT equipment and indoor use only'.

Is this something restrictive within this adaptor that might make it unsuitable?

a) INHERENTLY LIMITED SUPPLY SOURCE - A transformer, power supply or battery having no discrete protective device that is relied upon to limit the output energy available from the supply. A power supply or battery with internal current and energy limiting circuitry shown to be reliable is eligible to be identified as inherently limited. Transformers, power supplies and batteries may be provided with protective devices as long as they are not relied upon to limit the output.
b) NON-INHERENTLY LIMITED SUPPLY SOURCE - A transformer, power supply or battery having a discrete protective device that automatically interrupts the output when the current and energy output reaches a prescribed limit.

Originally Posted by BoomerangInfo

Also, how do you tell the right connector size? I see 2.1mm and 2.5mm adaptors in the Jaycar catalogue. That's kind of hard to eyeball the different. Does that size refer to the centre pin size

The sizing refers to the diameter of the centre pin. If you have a vernier gauge then this can be measured from the internal of the female plug end.

Bob Willson

Originally Posted by Bob Willson

The sizing refers to the diameter of the centre pin. If you have a vernier gauge then this can be measured from the internal of the female plug end.

Well in the end it didn't matter, as they didn't have a plug to fit anyway. So back to getting by with what I have until a better option presents itself.

You're having lots of luck lately aren't you Russell. It's about time that it stopped all being bad.

Bob Willson

Originally Posted by Bob Willson

a) INHERENTLY LIMITED SUPPLY SOURCE - A transformer, power supply or battery having no discrete protective device that is relied upon to limit the output energy available from the supply. A power supply or battery with internal current and energy limiting circuitry shown to be reliable is eligible to be identified as inherently limited. Transformers, power supplies and batteries may be provided with protective devices as long as they are not relied upon to limit the output.
b) NON-INHERENTLY LIMITED SUPPLY SOURCE - A transformer, power supply or battery having a discrete protective device that automatically interrupts the output when the current and energy output reaches a prescribed limit.

OK, so it has no discrete protective device, but limits the current anyway, so doesn't need protection? Is that right?

So is that still suitable to power the pump? The next cheapest thing I've found on eBay is this one AC 100V-240V Converter Adapter DC 24V 2.5A Power Supply | eBay. DOes that look OK? it's showing a standard 2.5mm connection at least by the looks.

Either one would probably be fine, but I would tend to under power it rather than over power it. It will tend to run cooler that way.

Bob Willson