Thread: G540Kit + VFD Build help needed

There's earthing for safety and earthing to reduce electrical noise.

The 240V earth connection via the IEC connector must be connected to the power supply earth (didn't read through the thread to see what sort of power supply you have but assuming a typical switching power supply such as sold by Homann Design, then it will have a earth connector which is also connected to the metal body of the power supply).
There should also be a connection from this earth to the chassis i.e. the metal box containing the components.
All this fails as a safety measure if your 240v mains supply does not have a suitable, functional earth connector as specified in AS3000:2007.

Originally Posted by snowyskiesau

There's earthing for safety and earthing to reduce electrical noise.

The 240V earth connection via the IEC connector must be connected to the power supply earth (didn't read through the thread to see what sort of power supply you have but assuming a typical switching power supply such as sold by Homann Design, then it will have a earth connector which is also connected to the metal body of the power supply).
There should also be a connection from this earth to the chassis i.e. the metal box containing the components.
All this fails as a safety measure if your 240v mains supply does not have a suitable, functional earth connector as specified in AS3000:2007.

Ok I've included some pictures as I'm still not sure.

Yes I have a Homann PSU. I can't see any connection on it as a ground. It's outside is pretty devoid of anything except screw holes for mounting to the base or sides.

In the picture, at the green #1 shows an empty red connector in the AC ground slot. So if I replaced that with one of the large yellow ones, and ran two wires from each of the IEC grounds (represented by the yellow lines) into the connector, and then another wire (represented by the pink line) out of that, and into the base (drilling a hole in at the pink X), secured by the bolt and ring connector shown in the second picture, would that suffice? As I said, I can't see a way to wire from the PSU connector to the PSU case.

On another note, the Jaycar stockist in Warwick may have the connectors I need, so I'm about to head in. I'd like to make sure I have everything else I need to finish the build off though, as I can see the light at the end of the tunnel, at least for hooking everything up, and I don't have any yellow connectors at this stage. I don't think blue will hold all 3 cables. The earth wire should be the same as the other AC wires, correct? I only have brown/blue in the extra heavy duty. The green I have is heavy duty, but I guess I shouldn't use that.

Thanks. Russell.

I just remembered but bunnings also have the connectors, they also sell 1mm2 earth color coded wire.

For your 240V female spade connectors you can also get some with a PVC jacket covering the whole connector so you don't have live connections just sitting there exposed.

Originally Posted by Ch4iS

I just remembered but bunnings also have the connectors, they also sell 1mm2 earth color coded wire.

For your 240V female spade connectors you can also get some with a PVC jacket covering the whole connector so you don't have live connections just sitting there exposed.

Well maybe normal Bunnings do, but regional Bunnings had only 2.5mm power earth wire, and they had the crimp/connector kit, but no connectors on their own. Rexel had packs of 40. They were really good, 415V rated, but I wasn't buying 40 connectors when I needed one.

Top beat had the 4.8mm female spades, even gave me 10% discount on the 2 packs I got, but no one had the yellow connectors in size or quantity small enough. My last resort was back to Supercheap, and they were sold out So I ended up grabbing a pack on the blue spade connectors there, and hopefully I can squeeze the 3 wires for the PSU hookup into the one connector.

Russell.

Originally Posted by BoomerangInfo

In the picture, at the green #1 shows an empty red connector in the AC ground slot. So if I replaced that with one of the large yellow ones, and ran two wires from each of the IEC grounds (represented by the yellow lines) into the connector, and then another wire (represented by the pink line) out of that, and into the base (drilling a hole in at the pink X), secured by the bolt and ring connector shown in the second picture, would that suffice? As I said, I can't see a way to wire from the PSU connector to the PSU case.

On another note, the Jaycar stockist in Warwick may have the connectors I need, so I'm about to head in. I'd like to make sure I have everything else I need to finish the build off though, as I can see the light at the end of the tunnel, at least for hooking everything up, and I don't have any yellow connectors at this stage. I don't think blue will hold all 3 cables. The earth wire should be the same as the other AC wires, correct? I only have brown/blue in the extra heavy duty. The green I have is heavy duty, but I guess I shouldn't use that.

Thanks. Russell.

You don't need to wire from the PSU to the case as you have already bolted the case to the PSU (I think you have anyway)

As to using a green heavy duty earth wire ... I don't think you can ever have too thick a wire to earth.

Originally Posted by Bob Willson

You don't need to wire from the PSU to the case as you have already bolted the case to the PSU (I think you have anyway)

Yes I have bolted it to the case, but do I still need to wire from the AC ground connection to the chassis?

Russell.

Originally Posted by BoomerangInfo

Yes I have bolted it to the case, but do I still need to wire from the AC ground connection to the chassis?

Russell.

You shouldn't need to as the case of the power supply is connected to the AC ground terminal of the power supply.

[I just checked this on my power supply which is a cheap knock-off of the Meanwell supply that Homann sells]

Originally Posted by snowyskiesau

You shouldn't need to as the case of the power supply is connected to the AC ground terminal of the power supply.

[I just checked this on my power supply which is a cheap knock-off of the Meanwell supply that Homann sells]

OK cool that will make things a lot easier. No drilling or bolting extra, and my blue connector will hold the two IEC earths.

Thanks. Russell.

Hi,

Proper wiring practices require you to bolt the earth from the power inlet to the chassis. A 6.3mm quick connector would not pass inspection. This is because, if the quick connector comes off, your chassis may not be earthed. Then, if the active comes loose and contacts the chassis you have a live chassis.

On my schematic, I shown the earth from all points bolted to the chassis. This is the correct way to do it.
http://www.homanndesigns.com/pdfs/EN010_V8.pdf

On my controller the Powersupply aluminium case is connected to the earth terminal on it. The Power supply is then bolt to the mezzanine plate, which in turn is bolted to the chassis. I don't use a separate bolt, but you could do.

Cheers,

Peter.

Ok thanks everyone. So I hope I've understood everything, and as far as I can tell, here's the internal wiring and assembly completed!

Only thing I haven't wired is the auxilliary relay outputs to the external connector, since I would have had to solder the external connector and I may never use it. if I ever do, it shouldn't be too hard to finish the wiring.

From here it's back to putting the DB9 BOB's on the stepper wires, then wiring up the control wires from the G540 to the VFD. From there it's onto the scary part - programming the VFD and finally, powering up!!

If anyone sees anything obviously wrong, please let me know, otherwise, thanks everyone for all the help, I couldn't have done it without you all

Russell.

It' a bit hard to comment as there's no attached wiring.

Cheers,

Peter.

Originally Posted by phomann

It' a bit hard to comment as there's no attached wiring.

Cheers,

Peter.

LOL, oops Try again.

A new day, a new set of problems. Looks like I celebrated prematurely.

I thought I'd give it a quick powerup check this morning, and I see to have a problem. After disabling the charge pump, as per the g540 manual, and turing on, the green power LED is not coming on. If I hit the E-stop, the red Fault LED comes on, so power is getting through, but that's the only response i'm getting from the system.

I cehcked all the plugs, everything seems to be tight and the wires are all secure. Should either the PSU or the gecko chiller fans be going, or are they temperature controlled, as neither of them are running either.

Any suggestions? Thanks.

Russell.

*EDIT*

OK, now I'm confused. I checked all the connections again, and powered up to see if the PSU LED was showing, and this time when I pressed the E-stop, the green power light came on and everythingbstarted running. I did swap the NO/NC E-stop connections originally, as I thought I had them back to front, as the fault lit came on immediately first time. The fault light should not come on when E-stop is pressed?

Given the situation with the fault light coming on originally whe. E-stop was pressed, and now it's the green power light coming on, what does that indicate? A faulty connection?

Hi,

If you are powering the Gecko Chiller directly off the 48V supply it should be running.
Also, the Fan on the 48V supply will also run, and there is a small power led on the 48V power supply. Additionally, when the G540 is enabled, with its green led is on, you will hear the fan for the 48V supply kick in to increase the cooling.

First think to do is check that you have 240V power to the 48V supply. You have put a fuse (5A) into the IEC power entry module?

Cheers,

Peter.