Gecko G540 Overview Part 2 The Drive, And Tips When Building Your Controller.

[@chrisgraves9601]

Thanks Vince...you have really helped me to understand more of what’s involved in the electrical side of my CNC build... Pieces of the puzzle are starting to come together better in my mind thanks to these 2 hours of detailed information. I really appreciate the keep it simple stupid reminders as well, that is great advice. I’ve been really enjoying your videos.. thanks for all your hard work.

[@corvetteguy50]

Chris thank you for your support I really appreciate it. Vince

[@Q5Grafx]

8:30 sanding before epoxy also increases the surface area making it dispel heat better. Just going through videos in the morning before the sun is up. only have the 3 vfd cables left to attach and the 9014 is completed. could have done it yesterday but it was so cold that once i was done with the soldering i just wanted a break. I give you credit on the gx16-6 connectors they were hard to do especially someone with hand tremors. i found the interior of cabinet side much easier than the cable side. it took me an hour to solder the 6 wires on the cable side. but i checked the cable with my meter and have conductivity to all wires at opposite end and no cross shorts so i guess its good. after this i have to come up with an efficient way of hanging the dust collector hose so it has full range of motion without interference. i have all subsystems set up on remotes so the pump is button A Compressor is button B spindle light is button C Dust Collector is button D and ESS is button E. the remote outlet setup i bought has 5 remote outlets i hooked up to my Tripplite 12 outlet 20 amp power strip. the PC and G540 panel are plugged into an ESP smart power monitor/filter. So far everything has worked flawlessly which makes me nervous. I still have to install the ESS drivers and software and then get to all the settings. i havent even opened up mach3 yet other than months ago as a familiarization. I also have to do some wire management to clean things up under the table. i cut the wires so they all run right under the table and drop down to the panel leaving 18" of play. Im looking into a fixture plate from Saunders Machine Works because the way the bed assembles leaves alot to be desired and i feel the added metal will also add rigidity. Sorry i went on and on again. Happy New Years Vince.

[@corvetteguy50]

Hey Dave, Happy New Years! It sounds like she's coming together very nicely. All the attention to detail will certainly payoff. Thank you, Vince

[@stephenjones4135]

DB9 sockets have huge connectors. Anyone should be able to solder a wire into those. Place DB9 connector in helping hands, apply a little flux on connector and bare wire, and fuse with high grade nickel solder with a chisel tip. Add small pieces of heat shrink to each solder joint for extra piece of mind (just covers to where wire was striped (safeguard against murphy). The most important step is to orient the pins correctly because desoldering things makes a mess and is sometimes frustrating. BTW, I saw on the silkscreen "R = 1K / Amp" just to clarify for some people, does that mean for every Amp there is a 1KΩ Resistor? For example, say we have a 3 Amp per phase motor, does that mean people should use a 3KΩ Resistor across those DB9 pins? What he was saying at ~28:20 was if someone is running their table axis (regardless if X or Y) and there is one motor on each side driving separate ball screws then someone can configure two motors to operate in parallel through Mach3. The point here is not to use one motor cable (axis) to operate two motors. You will destroy your motor driver, or the cable will heat up and there will be a short (destroying many things), or one motor simply won't work because current will flow to one motor, or you will get what he mentions at ~34:30. This is simplified examples but should make the point. What he mentions at ~37:00 is a kernel of wisdom. Bigger steppers do not mean better. They simply guarantee more cost and higher power consumption (point of diminishing return). When possible use smaller motors, gear the system, and reduce the speed of system. We cannot be in that big of a hurry to mill something is under a minute if we have the time to build a machine (makes no sense).

[@corvetteguy50]

Sierra, the resistor size to use is based on the motors size you choose. If for instance your motors are 2.8a the resistor should be calibrated to 2.8k (ohm) to match their amp rating (the resistor is connected at pins 5, and 1 on the DB9 terminals). The point you make about heatshrink being used on a DB9 connector termials is really an end user option as the terminals are designed to be put inside a DB9 enclosure preventing exterior shorts. Heatshrink can become a real issue to remove them in the even rework is required on terminal, so if you intend to use it make sure you check everything twice before sealing the terminals.Thank you,Vince

[@dr.gernotwehsner9662]

Hallo,at first thanks for your great Videos, now my question:Since a few weeks I own a Chinese 6040, now I change to Gecko g540 with UC100, an I use the latest Mach3 Software registered to me! You always say, that mechanic limit switches are not necessary, but I had a step-loss while routing, I got a destroyed piece of wood, and on the x-axis, where I had the step-loss, went into machine limits, I don´t think, that soft-limits could avoid this? What is your opinion?And, where can I find your online-shop?Nice regards from Austria, Gernot

[@corvetteguy50]

Dr. Gernot, thank you for your support. The issue with lost steps need to be analyzed as this only happens if the system has EMI penetration on the STEP, and DIRECTION signals, or the drive is run out of its stable operating envelope. Once you've determined the cause you'll take the required proper corrective action. Here's my video covering soft limits, and fixtures kzbin.info/www/bejne/sHfOkIhprtalodU in Mach3. Their not only safer, but much faster than physical switches as their essentially just GPS locations. This means instead of having to have the machine bounce off all the switches an end user has installed they simply select an offset they programmed press the button, and the machine goes to it to begin machining with digital accuracy. This is a much more efficient process than many operators use as they don't understand the true power of Mach. thank you, Vince

[@aloharandomvlogs9787]

Do you have a website? And do you sell kits? I have seen on another YT channel someone converting a plasma cam with Gecko drives while still using the servo motors from the plasmacam machine. I plan to switch to nema 23 stepper motors...would that still work with the Gecko 540 system you're talking about in this video? I have the plasmacam/samson 510 which is a 5 x 10 plasma cutting table. Please advise

[@corvetteguy50]

Aloha, Thank you for your support. I sell everything from kits, to complete turnkey assembled systems. Here's my store. www.ebay.com/str/edealersdirect Nema 23 motors will work fine with the G540. Thank you, Vince

[@aloharandomvlogs9787]

@@corvetteguy50 i am disabled. so finances is tight. i need a complete set turn key with nema 23 motors not sure oz. size. my gantry weighs nearly 50-75lbs. do you have a email we can correspond the specifics

[@corvetteguy50]

Please email me at [e-mail] and I can forward you a quote. Thank you, Vince

[@GeminiSeven43]

What Wattage Soldering iron do you use when soldering the DB9 connections? Great video for new comers to Gecko

[@corvetteguy50]

GeminiSeven43 thank you for your support. The soldering iron wattage can be as low as 40 watt's as DB9 connectors are very small. I do however recommend using flux for the strongest connections, and better flow out. Thank you, Vince

[@GeminiSeven43]

@@corvetteguy50 Thanks so much, I was curious because I am always worried about melting the plastic housings on the DB9 or similar connectors. it always seems to be a trade off between enough heat and having an iron tip that is small enough the get between the pins. Thanks again for all your help and good luck in your projects.

[@corvetteguy50]

@@GeminiSeven43 , thank you again for your support! Vince

[@watahyahknow]

kewl just starting building my cnc router and learning the electronics and operating system as i go the build is processing real slow , but slow is good it will give me the chance to investigate options and such (like using one steppermotor on the Y axis like you adviced in the video ) it will prolly will take me a year and a lot of bargain hunting on ebay for slightly used parts to get all the parts together as the monthly budget isnt that awesome ) one thing i whont skimp on is the stuff between the computer and the steppermotor , as from wat i seen a lot of the grey hairs are caused in this part the other stuff usually works or it doesnt seems to me this is the best thing to have to get started without immediately be deep inside the bob and stepperdriver wiring to check and check and check and..... if you done everything right , knowing it corectly hooked together takes some of the guessing out havent gotten to see the item yet so i'm just trowing this out there , i can buy one used that has a cooling body glued to the back (was too small for the guys machine it seems) : can you still open the body of the G540 with the cooling block on the back to get inside it , for instance to replace a blown driverboard ? nice and small too should be able to fit it somewhere under the bed / table of the cnc machine and only have long spindle power , power for the gecko , and serial cables run from my computerdesk to the machine might even put the VFD under the table too got some reading and video watching to do i take it you can operate the VFD with mach3 from hookups in the gecko and will read up on how to do it

[@corvetteguy50]

Take your time, and just research everything carefully as its allot to digest all at once. Thank you,Vince

[@Mikesplanes54]

Hi How do I set my geko to 4amps???

[@corvetteguy50]

Mike, Thank you for your support. The maximum amps the G540 supports is 3.5. Thank you, Vince

[@Mikesplanes54]

@@corvetteguy50 Hi Vince, thanks for that.Tow of my steppers get very very hot so you can't touch them what can I do please??

[@corvetteguy50]

@@Mikesplanes54 Stepper motor get very hot, and this is completely normal. kzbin.info/www/bejne/pabTqYqLr9yjhaM The G540 supports installing a resistor to allow the drive to enter idle current reduction mode when the motors are at idle extending their longevity. Resistors selection for the G540, is done using a linear current set resistor formula, meaning that every amp of current requires 1K of resistance. If your motor is 1.5A, then use a 1.5K 5% 1/4 watt resistor; if it is a 3A motor, then use a 3K 5% 1/4 watt resistor, and so on. Using the resistor allows the drive to enter "idle current reduction mode" this mode allows the driver to output only 70% current preventing excess motor heating. I highly recommend using the resistor even if your motors are rated 3.5a. Thank you, Vince

[@danielminskey]

Wow. thanx. very imformative. im looking at the gecko g540 for my cnc build. what power supply do you use?

[@corvetteguy50]

Thank you Daniel. I use a 48v 12.5a units n all my systems. I engineered the power supplies I offer for use with my systems. They provide about 1.5a of additional power when using four steppers with an RMS output rating of 2.7a of the G540's drivers. I suggest using caution on using smaller supplies if you ever intend on using four steppers, as the system will still need at minimum 9.5a. My system also provides ample power for an integrated 48v fan for your cooling system. Take care, Vince

[@lorriehatstat3449]

yes, it's a factory table that already has servos on it, but I will email you at some point to maybe discuss it more if that's OK with you? thank you for your help

[@td1830]

I have been reviewing and researching building my own CNC plasma table. I have basically found that the most confusing part is the electronics and software and gantry Designs. In your video you stated to use only one stepper motor to run a axis but most machines I see are using two steppers to run the xor y axis. I also saw on your store page you said theses are the same electronics that are used in the can cnc systems. I would like to build a 4x4 table with water box and torch height control. I would like to be able to use the Torchmate software to run my table along with fusion 360 and Inkscape any recommendations? Thanks Dale.

[@corvetteguy50]

DSG,Please contact me at [e-mail] to setup a time to have a consultation as we can cover far more ground, and answer all your questions to get you up to speed.Thank you,Vince

[@reinorapper]

Thanks for the video , great help as I am looking to buy one of your systems.

[@corvetteguy50]

Thank you. I'm hoping to take the confusion out of setting your system up correctly the first time. I look forward to providing you with the best system I can build featuring the G540. Take care.

[@reinorapper]

Is there a way to contact you to ask about your ebay package? www.ebay.com/itm/141727661999?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

[@corvetteguy50]

Just message me through Ebay, and send me your number, and a good time to call to discuss it. Thank you Vince

[@rarjmag5980]

reinorapper and

[@corvetteguy50]

I appreciate your kind words. I'm glad it was helpful. Take care, Vince

[@johnross3752]

have you ever blown a Rester ?

[@corvetteguy50]

Hey John, No I haven't experienced that. Thank you, Vince

[@mimimitchell1989]

My gecko 540 x,y,z, a axis are switched around .Y axis is correct but z=x ,and a=z . What could be the problem.

[@lorriehatstat3449]

I have an oxy flame cutter that runs by an electric eye tracing a pattern, and I would like to convert it over to cnc, thanks for you time

[@corvetteguy50]

Your looking to fabricate a plasma CNC system? Please message me at my email [e-mail] to discuss your system options. I don't think you'll need servos, but if you want to go that route its an option. Plasma systems perform excellent with steppers. They also make the systems overall cost much cheaper, and easier to maintain then servos. Thank you,Vince

[@jamesriddle3220]

Vince can you put up a link too your e-bay store. Thanks Jim

[@corvetteguy50]

The Store link is stores.ebay.com/eDealers-Direct?_trksid=p2047675.l2563 Thank you James,Vince

[@Shazzzam74]

Thanks for the great videos. I do have one question and forgive me if you went over it and I missed it but is there a place to connect limit switches? Thanks in advance.

[@corvetteguy50]

Adam, No worries. Limit switches aren't required as you have soft limits in Mach3 which provide the ultimate protection for your machine against crashes. A mechanical switch can fail, and if it does your machine is SOL. If the software crashes, or your computer does the machine simply stops. Remember the computer is the neurological center of the system. No computer equals no movement. If however you decide to add home switches the G540 has 4 inputs on its terminal block to add them. Thank you,Vince

[@Shazzzam74]

Ahhh. That's right. Just getting back into cnc and forgot Mach3 had that. You should be sending a gecko drive to Texas. Just bought one from you on eBay.

[@corvetteguy50]

Adam,I didn't receive your order. Did you purchase it from eDealers Direct?Thank you,Vince

[@ianbuttery8693]

Could you indicate fan placement relative to heatsink.

[@corvetteguy50]

The fan should be placed roughly one-two inches from the heat sink for optimal heat dissipation.Thank you,Vince

[@ianbuttery8693]

Thanks Vince. How many fans and what size do you use with the 540?

[@corvetteguy50]

It depends on the size of the enclosure, and the output CFM of the fans. I suggest no less than 60CFM in a 12in x12in enclosure. Thank you,Vince

[@mrbritcoinnakamoto2793]

hi watching for some time thanks for doing the vids what was your web site?

[@corvetteguy50]

Russell,Thank you for your support, and I wish you, and everyone else a very Happy Thanksgiving! My store is on eBay. eDealers Direct. Here's the link stores.ebay.com/edealersdirectVince

[@mimimitchell1989]

I build 2500lb mini army tanks, so I really need my homemade cnc plasma table going But I know nothing . My gecko 540 x,y,z,a axis are switched around.

[@corvetteguy50]

Tank Commander, please message me at my email [e-mail] and I'll forward you its configuration video. Happy Thanksgiving to you, and your family! Vince

[@algonacrobotics99]

Thank you very much for making these videos. I am fortunate to have 3 machines that we will retrofit using the g540 and this help me understand the basic. I am not a CNC experts, justa robotics coach trying ot save some money so kids can learn and use CNC to manufacture some of our parts... My questions is around using a converting device to use USB versus parallel port between g540 and cpu, what would you suggest? Our plan is to use Mach3. Thank you very much!

[@corvetteguy50]

Thank you for your support.The UC-100 USB motion controller is the unit you'll want to go with. It will allow the system to be controlled by any Windows operating system be it 7-10, and either 32bit, or 64bit, and either laptops, or desktops that support a USB input. You simply install the devices automatic installer, and your all set to bring the G540 to the year 2018.Thank you,Vince

[@algonacrobotics99]

So i did a few more research on this project today and it is not easy... thank you for putting all this info out there.... I am working on a LMR8800 or Light Machine CNC Router.... Router itself is a Bosch 1617. some pictures can be found here.... photos.app.goo.gl/mpIzLwW5hPzCaBXs1 So in a nut shell this is what i have so far.... 1- rewire each stepper motor with DB9 connector to the g540 using the pin diagram in the g540 instructions manual. I am not 100% sure on the stepper motor wires... Motor are SLO-SYN M063-CS06.. cannot find a good wiring diagram, any help with that would be appreciated. 2- power supply... i resolve myself to buy yours on ebay... i look at my old controller and though that i could re use some of it but i think it will be a lot easier to get a new one. 3- spindle... not sure how to handle by reading it look like it will be a simple on off switch and i can control the speed with the potentiometer on front of the machine. Would be nice to control using Mach3... should it be on a different controller or can the g540 handle that too?

[@corvetteguy50]

Algonac,I don't have the wiring diagram for those motors, but you can figure out the correct wiring by using the LED method outlined here to find the matching coils. kzbin.info/www/bejne/Z4acoZltiMSirJaIhe G540 supports the option for adding 2 relays to your system. This will allow manipulation of cycling the spindle on, and off. You can also control the spindle speed if you were using a VFD to control your spindle. Your system's stock setup doesn't.Thank you,Vince

[@lorriehatstat5819]

Can you use servo motors with the gecko 540, and do you have a power source, whats the price for a power source in the 540

[@corvetteguy50]

Lorrie, The G540 is a digital stepper based driver system. It doesn't support servos. The 48v 12.5a power supply is $85 through my store. Thank you,Vince

[@patrickcrist9586]

Vince I am building a 4 motor system (tandem Y) I'd like to go with the gecko I (maybe prematurely) bought (4) 3.0 amp nema 23's is it worth it to return them to upgrade to the 3.5 and eliminate the resistor? Do you just connect the motors that aren't pre-terminated with but connectors or solder to additional wire? I would also be interested in a gecko 540 with power supply in a case pre wired and ready to hook up. Also what are you thoughts on running the gecko via USB what kind of options can you offer?

[@corvetteguy50]

Patrick, I wouldn't return motors just for the resistor installation. The resistor is used to allow the G540 to go into auto current reduction which is 70% to control motor heating. I recommend using resistors regardless of the motors your using for longevity of your hardware. You have to assemble the DB9 male connectors that come with the G540 using your motors output diagram, in conjunction with the G540's motor wiring diagram. You must use shielded cable to protect the system from EMI noise. A G540 motion control system with a USB converted PC input is the simply the way to go to allow the use of any Windows operating system, be it 32bit, or 64bit. You can also use laptops which I love. If your budget supports the upgrade I highly recommend it. Thank you,Vince

[@patrickcrist9586]

corvetteguy50 Vince do offer a package with a power supply, g540, case, with or without the smart stepper?

[@corvetteguy50]

Yes I can put together any thing you require for your system. Please send me your email for pricing details.Thank you,Vince

[@lorriehatstat3449]

do you have something that would work to drive servo motors?

[@corvetteguy50]

I can offer Gecko servo drivers. What are you building? The more detail you provide the better I can assist your requirement for your applications. Thank you,Vince

[@drumstick9000]

how do we go about shielding the DB25 parallel cable?

[@corvetteguy50]

Drumstick, Thank you for your support. All DB25 cables come factory shielded. Thank you, Vince

[@scottl8066]

Thanks for posting the video, I love your channel. I just got a g540 and steppers, but need all the rest, how can I find your store on ebay? Searching 'edealers' doesn't give me anything, I'm sure I could find it with more searching, I'm just eager to get everything I need to complete this build 😰

[@scottl8066]

Nevermind, found the store, I was just being impatient

[@howdareyousaymyname]

Kinda confused...around the 20 min mark you say 6 is /b yet the gecko manual says b and 7 /b. does this even matter..ie is it something that can be changed on the mach3 end?

[@corvetteguy50]

Please review the video closely, and download, and review the G540's users manual. In the video at 18:37 I begin to cover the motors wiring, and explain the pins allocation to motor wiring. 6 is B-, 7 B+, 8A-, and 9 is A+. The motors must be hooked up in this configuration to prevent any possible drive issues. This is correct, and can be verified on page 7 after you download the G540's users manual here www.geckodrive.com/images/cms_files/images/G540%20REV8%20Manual.pdf Remember /B in the manual means B+Mach3 can't rectify this issue if you hook the motors up incorrectly.Thank you,Vince

[@howdareyousaymyname]

Thanks for your reply, turns out i have had some of your items saved on my watch list. I am now more confused than ever, I either have my untested motors wired perfect or not at all. Seems half the cnczone threads i looked at say /b is negative. On top of that my motor wiring diagram says red a+ blue a- green b+ black b+ and then simply ac bd.

[@corvetteguy50]

I always warn of using forums as a direct knowledge base as you never know who your receiving information from. The users manual for the G540 is always the last word on understanding the pinout for any hookup. One more thing to review closely is your motors wiring colors, and polarities. Use your motors wiring diagram, and match the polarities to the G540's using its users manual. The colors of the motors leads don't matter as most motors will always be different as long as the polarities are matched properly. Thank you,Vince

[@robertschmitt9160]

What's wrong with LinuxCNC?

[@corvetteguy50]

It's fine if that's what you prefer, but Mach 3 will provide more options for in depth setup, and control.

[@raifhanna1120]

for the machine here,i want to know how to order the piston to comes down before the rotary knife starts cutting along the gantry(kzbin.info/www/bejne/hJevlauPmdajjM0) thanks in advance

[@RonnFolk]

If Gecko recommends heat sinks why don't they just put them on the drives.

[@corvetteguy50]

Hey Ronn, thank you for your support. You can ask them that question at Geckodriv.com No system manufacturer should sell a Gecko, or any other drive without a heatsink as its simply asking for temperature issues. Thank you, Vince

[@RonnFolk]

@@corvetteguy50 What is the name of your Ebay store?

[@corvetteguy50]

@@RonnFolk eDealers Direct Here you go.www.ebay.com/str/edealersdirect Thank you, Vince