Thread: G540Kit + VFD Build help needed

OK my G540 kit arrived yesterday, and I have some time this afternoon, so I thought I'd make a start. I went down and cut the power cord off my old drill and There's no earth wire, even though it has an earth pin

Now to try and find another cord I can cut up

Bunnings sell cheap extension cords for a few dollars, I've used them a few times for 240V projects.

Originally Posted by Ch4iS

Bunnings sell cheap extension cords for a few dollars, I've used them a few times for 240V projects.

Yeah I almost bought one at the Reject Shop the other day, for about $5 I think. I managed to find an old sandwich maker that I was using to do resin ribbons for my pens - still had the cord intact, and it's 3-wire it's only about 50cm long though, so might be a bit short. Good practice at least.

So, I've assembled the enclosure, now to figure out where the G540 is to be placed within the box so I can cut a hole for it.

*EDIT*

Here's the bits ready to go.

*EDIT #2*
I should be good to go if I follow the pictures in this thread https://www.woodworkforums.com/f170/g...-build-110937/, right?

I've moved back to the VFD while I ponder over the G540 layout. I think I've finished my first step! Brown is wired to 'R', Blue to 'T' and Green to Earth. Sound right? If I've got this basic step wrong, heaven help me.

Originally Posted by BoomerangInfo

If I've got this basic step wrong, heaven help me.

Hi, It's God here. Sorry, but I don't know much about this new fangled electronic stuff.

I'll ask a few of the angels but don't hold your breath.

See you when you turn it all on then eh???


God

Originally Posted by Bob Willson

Hi, It's God here. Sorry, but I don't know much about this new fangled electronic stuff.

I'll ask a few of the angels but don't hold your breath.

See you when you turn it all on then eh???


God

LOL, thanks for the vote of confidence

Well here's my bits for the controller payed out how I think they should go. I have a few questions though.

1. The power supply has screw holes in it everywhere, but didn't come with any screws, and aligning the holes to try and drill watching holes in the enclosure to screw into will be nigh on impossible. How do you mount the power supply?

2. I've got the chiller temporarily mounted on the G540. It's got a LOT of extra cable on it. Do I just leave it all tied up as is?

3. There's a fuse slot on the main switch, but no fuse was provided. What fuse do I need to get to go in here?

4. Does the ventilation holes look OK? I've got it coming up under the G540 chiller, and he top is over the fan on the power supply.

5. There's a green and a red side on the E-Stop, and 2 terminals on each side. Peter's wiring diagram show one wire in & one wire out. How do the two relate?

Thanks. Russell.

Originally Posted by BoomerangInfo

1. The power supply has screw holes in it everywhere, but didn't come with any screws, and aligning the holes to try and drill watching holes in the enclosure to screw into will be nigh on impossible. How do you mount the power supply?

For mounting holes I draw it up in Sketchup and print it out on adhesive paper, stick it down, center punch it and drill, or you could draw it on paper then stick it down and punch it, would be easier than trying to work around the curves of the base. Or if Meanwell provide a PDF with 1:1 scale you could just print that out and use it as a template.

3. There's a fuse slot on the main switch, but no fuse was provided. What fuse do I need to get to go in here?

Look on the PSU it will tell you the rated amps and get one closest to that. The standard quick blow fuses Jaycar sell will do the job, I believe you need a 5x20mm fuse.

5. There's a green and a red side on the E-Stop, and 2 terminals on each side. Peter's wiring diagram show one wire in & one wire out. How do the two relate?

One side is a NO switch and the other a NC switch, the G540 needs the NC side to be used otherwise it'll just fault.

Thanks. Russell.

Reply in red.

with the mounting of components
i masking tape up the back , measure it out with a ruler ( square of the edges of the box ) , mark the centres , double check , then drill , if there a bit out when screwing in , unscrew it all and adjust , finding screws to fit is the hardest part , most PSU's can be mounted on there side , there is a lip in the casing with a slot one end , and a hole the other , use those , should be able to lay it the box and mark the holes with a pencil

3. There's a fuse slot on the main switch, but no fuse was provided. What fuse do I need to get to go in here?

. also add the Amps that your output relay will use


with your wiring up "there" you are doing something very dangerous , could end up deadly , if you scratch or burn that kitchen table SWMBO will murder you

Originally Posted by SawDustSniffer

3. There's a fuse slot on the main switch, but no fuse was provided. What fuse do I need to get to go in here?

. also add the Amps that your output relay will use


with your wiring up "there" you are doing something very dangerous , could end up deadly , if you scratch that kitchen table SWMBO will murder you

The PSU says 240v/4A, but the two relays say 240V/30A. I doubt that means I should get a 64A fuse though, does it?

Not sure I even need the relays, but I'd like to put them in for future use. One as a switch for the pump (which is DC) might be useful, but not essential, and the VFD will have a separate power line anyway. What else would you use it for in my simple setup?

As for the table, you aren't half wrong, especially since it's only a couple of months old. But, given she drilled a hole through the last table by accident, I think I have one get-out-of-jail-free card

Originally Posted by BoomerangInfo

The PSU says 240v/4A, but the two relays say 240V/30A. I doubt that means I should get a 64A fuse though, does it?

Not sure I even need the relays, but I'd like to put them in for future use. One as a switch for the pump (which is DC) might be useful, but not essential, and the VFD will have a separate power line anyway. What else would you use it for in my simple setup?

As for the table, you aren't half wrong, especially since it's only a couple of months old. But, given she drilled a hole through the last table by accident, I think I have one get-out-of-jail-free card

the relay can used by the Mach3 screen , so any bit cooing pumps ( not recommended with wood ) , water cooing pump for the spindle ( but i would connect that up with the spindle , so when the spindle VFD is "on" the cooing pump is running ,

Are you plugging your VDF into that output ? remember to stay below 10 amp , your fuse in the shed

dust extractor ????? a few Amps there ( small vacuum cleaner(cyclone) )
you need to allow for what is plugged into the relay , the 30Amp on the relay means they can handle 30Amps before smoke and flames start coming out

with the PC
VFD 7amps
PSU 4Amps

lights
fan , beer fridge

you might need a second 10Amp fuse and wiring in your shed ,
cant have you turning off the beer fridge in summer

your spindle will pull 7amp under heavy load at full rev's , less when just spinning with no load , the PSU's 4 amps will only get used when all motors are running hard ? whats the max 48volt amps ,compared to what will your steppers use ( 3x 3 amp motors ) , so 9 Amps 48volts

watts , divided by volts will give you amps , so 500 watts / 50 volts , is 10 amp

Originally Posted by SawDustSniffer

with the PC
VFD 7amps
PSU 4Amps

lights
fan , beer fridge

you might need a second 10Amp fuse and wiring in your shed ,
cant have you turning off the beer fridge in summer

your spindle will pull 7amp under heavy load at full rev's , less when just spinning with no load , the PSU's 4 amps will only get used when all motors are running hard ? whats the max 48volt amps ,compared to what will your steppers use ( 3x 3 amp motors ) , so 9 Amps 48volts

Yeah I'm wondering if the supply will take it too. Even with multiple power points, it's all running through one circuit I think. The pump is rated 1.2A also, and the PC and screen will be on at the same time. I have a dust extractor, although I hadn't considered whether I need it for the CNC or not. Not sure what rating it is. Also don't forget I have a 4th axis too.

*EDIT*

PSU DC output is 48V/7.3A

Originally Posted by BoomerangInfo

Yeah I'm wondering if the supply will take it too. Even with multiple power points, it's all running through one circuit I think. The pump is rated 1.2A also, and the PC and screen will be on at the same time. I have a dust extractor, although I hadn't considered whether I need it for the CNC or not. Not sure what rating it is. Also don't forget I have a 4th axis too.

*EDIT*

PSU DC output is 48V/7.3A

the 4th axis will be used when the y axis is over the chuck and stationary , when using your Yaxis , you wont be using your A axis ( 4th )

steppers are pulsed so proberly only use there rated power 1/2 the time ?? not sure , not like a normal motor , other guys say its fine , it must work

dust and PC's dont mix

you should have 2 extra 10amp circuits in the house , can you run extension cords out , over 25meters ( 2 cords ) i'd de-rate them to 7-8 amp max , run your PC off a house power point

with the Pump running at 1.2 Amp , that would be at 20volts , not 240 volts , huge difference , so the pump will draw " a bit less than bugger all " properly 0.1 amp at 240 volts + 20% for a transformer , or 10% for PSU

Originally Posted by SawDustSniffer

you should have 2 extra 10amp circuits in the house , can you run extension cords out , over 25meters id de rate them to 7-8 amp max , run your PC off a house power point

Not as a long term solution. Shed is about 20 - 30m from the house. The line from the meter box to the shed has a bore bump point half way, which I think is a separate circuit, but even so, not the best to run a cord from there all the time.