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I purchased a used Hardinge DV-59 / OmniTurn. It had only control of the slides; no relay box or VFD for motor control.

I used the published OmniTurn schematics to make a relay box and added a...

Perfect. Thanks!

I wrote a macro that uses InputBox to enter the length of a part. The G-Code then compensates for variations in each part length as they are castings.

When I load my program, it halts until I...

Accel setting for Sherline Rotary cutting Wax?

I just converted from TurboCNC to Mach3 (wish I had done so sooner:)

I'm curious what folks who cut wax rings use for accel & speed on their...

I've had good luck with a 1/4" diameter wire brush and oil. I had to fabricate a brass tube to cover all but the last 1/16" of the brush. The tube prevents the brush from flaring out over time. I...

Yep - DIP switches are the way to go. Hope the case does not need to be removed for access.

I'd gladly pay the mark-up for the DIP in return for not having to locate and solder a resistor. Less...

Having built stepper systems around Gecko drives, including the G540, I'm pretty comfortable working with them. However I am new to the world of servo motors.

I have a 20 year old Omni-Turn CNC...

As a G540 owner and lurker in this thread, I'd like to see a definitive statement about board compatibility. I was under the impression all 4 axis were the same.

Is this an issue with all revs of...

I'll second the motion (pardon the pun) on TurboCNC. It's solid and you can't get much simpler than DOS for timing and pulses.

As mentioned, just give it a try if for no other reason than to...

I would hope the sniffer becomes available as a finished product by someone.

Unless someone is a CNC system integrator, I don't think a hobbiest will take the time to assemble one. It's easier to...

Sounds like an application-specific, poor man's logic analyzer.

The guys who integrate and build CNC systems would love it.

How about looping the tested pins through the Pulse Sniffer, latch...

Yep - Ohms Law proves your point. Case closed.

When I was an Air Force electronic tech years ago, we had a guy from the radar shop bring in five very expensive microwave detectors - all blown up...

Sounds like you need to do some major "shot-gun" troubleshooting. That is, swap out the PC and cable as others' suggested.

I think tweaking your pulses is just masking a more fundamental problem....

... l also agree that if Mariss designed them for 1us step pulse and Jason is having to run them with 10us step pulse for his program to run properly, there is probably something else going on ....
...

Am I the only one who feels this has been a random, hit & miss approach to troubleshooting?

If it were me, I'd forget about my program, hook up a dial indicator, and test each axis individually...

Mariss,

Don't lose any sleep over that call.

Think about it - if his mfg. operations were truly down and he was in jeopardy of losing a contract, he would have spent $500 plus FedEx for 5 new...

Now I'm really confused by all the rev changes. I have an early rev G540 ( no VFD output) and wondering if the drives have auto current reduction or not.

Often when a job is finished, I may not...

Gecko's "step motor basics" pdf says:

"If a linear regulated or a switching supply is to be used, then a large capacitor should be placed across the output terminals. A 2,000 to 10,000 uF...

Re: Solid State Relays

For my Taig mills I plan to do the following:
Use Crouzet/Gordos Solid State Relay Part# G240D25, 25 amp, 24-280 vac, 3-32 vdc input.
Remove the Taig power switch and...

I have two Taig CNC mills for my business and I'm always puzzled when people try to max out the top speed on these little machines.

If my business success was dependent on how fast I could rapid,...

"... It concerned the G540 and his CNC Brain device."

I first read about the G540 and the CNC Brain at about the same time. My first thought was, would these two play well together?

I hope to...

"...OMG, this has really gone off topic!"

We'll anything is better than the flamefest of a couple of days ago.

As for me, I'm gathering odds & ends to get my G540 & Taig Mill system built.
...

Reptile Dysfunction is normally fixable and should be covered by warranty.

And if you should experience motor resonance lasting longer than four hours, contact the manufacturer immediately.

Ed

So it's OK to connect a motor with a slightly higher current rating and the G540 will limit current as defined by the selected resistor?

Ed

If I mount on the surface, or flush with the PC metal case, I plan to keep some distance from the PC components.

The G540 comes fully enclosed in a metal case, and the motor cables will have...

My G540 arrived today. I was aware of the dimensions, but still my reaction was, "This is tiny!"

I held it up to my tower PC (metal case) and it looks like it can mount externally on the front...

Yes - but are there any differences in motor performance and system reliability between a switcher and a linear supply?

For example, can a switcher absorb the power when the motors decelerate...

When considering a power supply for the G540, are there any reasons (beside cost & size) to pick a switcher over a linear supply? Pros & cons of each? My main concerns are motor performance and...

... wiring adds up to at least 24 hours of labor.

Yep - and then there is making the front panel connector cut-outs, triple checking for wiring errors, making sure no little strands of cut wire...

That's great news!

BTW - I built my one and only 4-axis Gecko controller in 2002. Gets about 6 hours use per day. It has worked without a single problem all this time.

The real cost in...