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Rather annoyed. The insulation on one of the motor cables from my G540 fell off and some of the wires may have touched the frame. Now the fault light is on permanently, even after repowering a number...

Thanks Andrew,
I'll start hunting local suppliers via the web as this is my preferred solution. Nothing more frustrating than losing steps right in the middle of a job....

Thanks for your advice and the issue with high inductance was concerning me.

I would love to use servos, but the cost is a bit prohibitive here in Melbourne, Australia. Unless someone knows of a...

Hello,

I'm looking to upgrade the stepper motors driving a rather heavy Y-Axis Gantry on my homemade CNC router table. I'm currently using a G540 to drive 2 X 387 oz-in stepper motors on this...

Thanks to Peter, testing of the unit proved that there was nothing wrong. When I reinstalled it, it worked fine much to my surprise.

I can only assume that there was a loose or crook connection,...

Peter,

Thanks. I'll drop it off over the weekend.

Hi Mariss,

I heard from a colleague that there may have been some issues with some revisions of the g540 when slaving 2 axes via Mach3. I recently changed my design to slave my y and a axes and it...

Thanks Mariss,

I'll follow your instructions this weekend and report back.

Thanks Richard

Hello,

After 6 months of use, my G540 suddenly stopped working halfway through a job and is not responding to anything. The fault light is continuously on - even after re-powering a number of...

Hi Geoff,

That's correct ie connect the earth wire back to the inverter 'E' terminal. Make sure that your mains 240V supply earth is also bonded to this 'E' terminal as well (along with any other...

Raider,

Here are absolute minimum settings on the WJ-200 for my 400Hz 2.2kW spindle. It assumes that you are manually running the spindle from the control panel (ie not from an external source)....

Good luck Rory, that's quite a large machine you're building there!

I'm very interested in how you go the second time around. There are many things that I would do differently if I had the funds...

Agreed, he didn't pack my screws and rails very well despite my request to take care in this area. However he communicates well and the spindle came well packaged in dense foam.

Guess that's the...

Hi Merlin,

My suggestion is to build from scratch using good components recommended by others in these forums. It's very rewarding (sometimes very frustrating!) and I guarantee that you will enjoy...

Hi Merlin,

I sourced the spindle from Chai at linearmotionbearings. He has a good reputation within cnczone,

linearmotionbearings2008 | eBay

The Hitachi WJ200 VFD came from a company in the...

Worked it out. Just needed to wire one of the g540 outputs to a 48v relay. On the relay side, I ran one of the wires to the WJ-200 digital input 1 and the other to ground. Then set A002 to 1 which...

Update on stalling issues.

I purchased three new 387oz-in steppers and tried one of them on the troublesome y axis. The improvement was quite noticible and I can now get rapids of up to 3,500mm...

Another question.

I'm using a Gecko G540 controller and have been able to use the 0-10v analog output to control the speed successfully on the inverter. However I'm keen to also control run/stop...

Hi Chris,

for your size of table, I'd recommend that you use two screws for the Y-Axis. I used one 25mm screw and whilst I don't have any racking issues, the single 380 Oz-in motor stalls too...

For small quantities, I've used off-cuts galore on ebay or quicksales

offcuts.galore | eBay

Cheers,

Richard

Looks nice and solid and uses dual rails similar to my own build. My advice is to build in some adjustment to the rails as I found alignment as my biggest frustration. I'd really encourage you to...

Mactec54,

thanks again for your help. From your experience, what's the lowest frequency that these spindles will operate at without losing too much torque (or getting too hot)?

Or is this a...

Thanks to Mactec54, I've found the problem and it came down to a single setting on the inverter.

A003 – spindle base frequency was set to 50Hz and changing it to 400Hz fixed the problem. This is...

Thanks Mactec54, I'll compare these settings to mine and report back.

Richard

G'day Josh,

saw your build post recently and have been watching with interest. Wouldn't it be good to turn back the clock so that you could do things differently? Still, making mistakes is the...

Thanks Paul, I'm already using a new amphenol plug and socket but I will now open the spindle up again and double check everything. Good point about checking winding resistance to see if there is...

Thanks for your reply Wayne.

Looks like I'll have to replace mine. Damn - haven't even had a chance to use it after I purchased it 12 months ago from a dodgy ebay operater.

Regards,

Richard

Good thought, but I had already changed the plug before I started using it.

G'day Wayne,

Looks like I have the same winding issue with my 2.2kW spindle. Did you have any success fixing yours?

Regards, Richard

It now appears that the VFD is OK as I managed to connect a different 3 phase motor and it worked fine at 50hz.

So it looks like I have a problem with the spindle. Any ideas as I don't think I'll...