As mentioned in a couple of other threads, my chinese CNC controller has blown up before I even got it working. I've ordered a Huanyang VFD, and am looking to get a G540 Kit (
G540 Stepper Controller Package (No motors included) [CC-01] - US$360.00 : Homann Designs!, The preferred CNC Component Supplier) with the enclosure and hook it to the VFD.
So what I'm looking for is a complete list of parts & tools I need to build it all. I've read through the VFD thread, and Peter's wiring diagram for the G540 kit, and mos tof that I at least understand the diagrams, but I'd like to identify the external construction skills more than the internal connections and settings.
So, this is what I think I need. Please let me know if I've got something wrong or what am I missing. Assume I'm starting with nothing.
G540 side
1. G540 Kit, including enclosure
2. Soldering iron & solder (I have beginner+ level soldering skills)
should be fine as most connections to the G540 are by screw terminals. The DB9 connectors can be a little bit fiddly but nothing too complex.
3. 240V power cord to power the G540 (old computer power cord)
yep
4. (optional) Gecko chiller cooling fan (is this needed/recommended?)
i bought it with mine just to be on the safe side and was a breeze to install.
5. Parallel computer cable (my computer has a parallel port)
yep
6. Lots of wires to wire the components together, including wires to VFD (specification and estimated length?)
this will depend on how close you want to have the VFD to the controller enclosure.
7. 4 current set resistors for the steppers (to attach to the included DB9 plugs)
I also bought the DB9 connectors with the built in potentiometer included
8. Wire cutters & strippers to remove the current round plugs on my stepper cables
yep
9. Dremel to cut holes & drill/screw in the enclosure to mount components
I just used a drill, hacksaw and file but a dremel would certainly make life easy.
10. (optional) enable switch (?)
I did.
11. Multimeter to check connections
Definitely - to check continuity etc.
VFD side
1. Huanyang VFD
2. Standard 3-pin power cord, female end removed, wires bared(should they be tinned and/or have eye (or spade) terminals on them?
Eye Terminal - Red - Pk.8 - Jaycar Electronics)
Up to you really. mine will be bare wire twisted by hand.
3. Cable to spindle (Plug cut off current spindle cable and cables bared & tinned?)
I bought the cable from AusXmods that was perfect for this connection.
Ok so now some questions I'm not sure of.
a) My current setup has a 24V/1.2A rated water pump, being powered via a round, 2-pin plug coming out of my control box. It runs as soon as power is applied to the box, and is about the only thing that still works on the original controller. How would I integrate this into the new setup. Is it possible to get the 24V supply out of the G540 or the VFD, or do I need a separate power adaptor & suitable connector (or replace the round connector with something compatible?) I understand the relays from the G540 can be used as control sources, but I'm talking more about powering the actual pump. Suggestions appreciated.
You won't get power supply out of the G540 other than the 10V to send to the VFD if you control it via Mach 3 (or similiar software) This will require another 24V PSU or if you can use the one out of your other box. Might be best to start fresh given the headaches you've already had.
b) Peter's wiring diagram shows DB9 connectors to the outputs (VFD, limit switches, steppers). I know he did this to break the diagram up conveniently, but would anyone suggest actually wiring up this way to make parts easily moveable, or is it just a waste of connectors to do it that way?
Up to you - some people like things to look neat and tidy - others don't give a rats..
c) Powering everything. Given I've blown up one motherboard already, and tripped the RCD more times than I like, can anyone confirm the current requirements of all this.
- The Spindle is 1.5kW, the VFD description says 7A.
- As I said the pump is labeled at 1.2A.
- My PC has a 500W power supply, but is only running the mobo, 1Gb RAM, the HDD and a Geforce 8500GT.
- My small 17" LCD monitor.
?? Couldn't confirm this one for you?? This will probably depend on the RCD you have installed and what capacity it has.
My shed has a small sub-board running from the house meter box, with 1 mains for power, and another for lights. I have 3 double power points spread around the shed to use for my woodworking machinery. They are 10A circuits I think.
Should I be alright running all this?
Sorry, I know that's a lot of info, but I want to get it right before I spend more money this time, instead of finding out after I get it that I've over specced, underspecced or bitten off more than I can chew.
Thanks for help with any of this.
Russell.