Thread: Gecko G540 CNC Kits now available

I know that phomann is gone for the next couple of weeks, but i received my CNC electronics package for Christmas and am having a little trouble following the wiring diagram that he has put together. i am hoping that someone will be able to help me out. My question is in regards to the relays. What is the purpose of the second IEC socket and the Auxilary Socket Output? If i follow correctly, the first socket is the main power (effectivley plugged into the wall) and from there it goes through a relay and output2 to power another socket. however this socket would be at 48 volts or whatever your power supply is, correct? and the Auxilary Socket Output would just be a standard recepticle?
Also, i would assume it would be possible to connect all three grounds into power IEC so that it was all grounded through the main power cord. It is drawn as seperate grounds and i just want to make sure there is no reasoning for this.
Sorry if these are very dumb questions, this is all just so new to me. Thanks!

The relays are 48 V relays - this means they have a 48 V coil which switches (in this case) the 240 V active. This allows a 240 V device to be switched ON / OFF by the Gecko controller.

Shoule add that the switched 240 V outlet should be a female outlet. Something like the Jaycar PS 4002:

IEC Chassis Power Socket Female - Jaycar Electronics

This will stop inadvertent contact with the 240 V when it is live.

Ok, i think i understand that part. the neutral that goes to the IEC socket is straight from the 240V, and the live wire that goes into the relay is controlled on/off by output 2 from the Gecko. Would this be used to switch the spindle on/off? So i would connect my VFD to the socket, and then my spindle to the VFD. this would switch it on/off and also be able to control my speed via Mach3. What then is the Auxilary Relay Socket accomplishing? That doesnt seem to be connected to power anywhere? Again, sorry if these are very simple questions, i am much more of a mechanical guy than an electrical guy.

Originally Posted by t_brown

Ok, i think i understand that part. the neutral that goes to the IEC socket is straight from the 240V, and the live wire that goes into the relay is controlled on/off by output 2 from the Gecko. Would this be used to switch the spindle on/off? So i would connect my VFD to the socket, and then my spindle to the VFD. this would switch it on/off and also be able to control my speed via Mach3. What then is the Auxilary Relay Socket accomplishing? That doesnt seem to be connected to power anywhere? Again, sorry if these are very simple questions, i am much more of a mechanical guy than an electrical guy.

Yes you could power your spindle off the IEC socket controlled by the relay. Keep in mind the total current requirements as the IEC/fuse/stitch block is rated to 10A.

As a VFD is a control device in itself, there is probably no need to switch the power to it via the mains. It is more likely that you would use the 2nd relays contacts to start and stop the spindle.

The 2nd relay's contacts could be used for activating the FWD input contacts on you VFD.

Cheers,

Peter.

Hi all,

Happy New Year.

I've done a few small updates to the schematic. Nothing major. It is now at Version 5 and can be found att he bottom of the following page.

G540 Stepper Controller Package [CC-01]

Also, I'm including an IEC female socket in the Kit now, along with a couple of freewheeling diodes for the relays.

Cheers,


Peter.

Originally Posted by phomann

Yes you could power your spindle off the IEC socket controlled by the relay. Keep in mind the total current requirements as the IEC/fuse/stitch block is rated to 10A.

As a VFD is a control device in itself, there is probably no need to switch the power to it via the mains. It is more likely that you would use the 2nd relays contacts to start and stop the spindle.

The 2nd relay's contacts could be used for activating the FWD input contacts on you VFD.

Cheers,

Peter.

I am sure everybody but myself understands what the above means.
Am i right in thinking that if i follow the g540 wiring diagram that shows the three wires going to the VFD the 10v output will switch on the VFD? (So there is no need to use the 240v plug.) I hope this makes sense.
Thank you for your patience

Hi Triden,
Electrickery or mumbo jumbo talk.
Nah you still need the 240 connected to the VFD. What Peter is referring to is switching / controlling the VFD through the gecko and Mach3.

Thanks Rod.
How embaressment
After CAREFULLY reading some other posts i understand what you and Pete are saying. The three wires control FW/REV Speed ect.

Originally Posted by triden

Thanks Rod.
How embaressment
After CAREFULLY reading some other posts i understand what you and Pete are saying. The three wires control FW/REV Speed ect.

Nope. Still not quite right. Since the diagram is not clear to you, it is the diagram that needs revising. So I'll do that.

What I'm trying to say is that;

1. The 240V of the VFD plugs into a wall socket
2. The G540 has 3 wires for producing an isolated 10V control voltage that can be used to control the spindle speed, and connects to the VFD's analog control input terminals. This is what is shown on the schematic.
3. In order to make the spindle start you still need to switch the FWD control contacts on the VFD. This is not shown on the Schematic. I'll change it to show the 2nd relay's contacts switching the FWD input of the VFD.
4. The 1st relay that switches the supply voltage (240V) is not used at all with the VFD and can be used to switch a dust extractor, cooling pump, or air-conditioner if your shed is anything like mine.

I hope this is clear.

Cheers,

Peter,

Pinnnng
The penny has droped Thanks pete
Cheers

Hi,

I've updated the schematic to show a clearer VFD connection. The diagram is in the usual place on the CNC Package page.

G540 Stepper Controller Package [CC-01]

Cheers,

Peter.

Hi Guys, Im looking for a little assistance in the maths required on the motor tuning. Im currently using a Widgetmaster and it looks like 10 revolutions on the acme thread give 1 inch. So what should my Steps per MM be? and what about the Step Pulse? 1- 5?

I think I need to get rid of the laptop. I was 1/2 through milling and the machine lost some major steps. It kind of made a squeel noise and mach3 thought it was moving but the motor was stationary. The same thing was happening with my Xylotex driver. Once removing the job it was then that I noticed the job was too small... so my steps per mm must be out? or step pulse... or something?

Is this how you work it out....

10 rev per inch on the acme thread = 10 rev 25.40mm or 1 rev per 2.54mm.

Stepper motors are Step Angle1.8 degree (200 spr)

G540 10 micro step driver.

200spr x 10 ms = 2000 / 2.54 = 787.401 ?

What about Step Pulse?

Any assistance is appreciated.

Brad.

Hi Brad,

Set your machine units to inches as that is what the widget master is. If you always want to work in metric, then put a G21 in the initialisation string.

For the G540 (G250), yes it is a 10 microstep. So

10 microsteps x 200 steps/rev x 10 revs/inch

So that's 20,000 steps per inch.

As to the step pulse, set it to 1 or 2.

Cheers,

Peter.