[argon blade]

i just got my taig / gekco 540
the wires that the motors came with are getting way too hot! like 190'
i was wondering if i was the only one with this problem and if any one else had solved the problem

[Jeff-Birt]

I suspect your probably using regular DB9 serial cables. These use 28 or 30AWG wire and are totally inadequate for use driving a stepper motor. (And yet some places keeps selling them to unsuspecting folks.)

You should make or buy cables made from good quality 20 to 22 AWG stranded wire. (That is what I use for the ones I build).

[argon blade]

I suspect your probably using regular DB9 serial cables. These use 28 or 30AWG wire and are totally inadequate for use driving a stepper motor. (And yet some places keeps selling them to unsuspecting folks.)

You should make or buy cables made from good quality 20 to 22 AWG stranded wire. (That is what I use for the ones I build).

thanks jeff

it is totally stupid that the company ships these substandard wires...
mind you that this all happens during set up ... i have yet to run a program of any real length....

so my next question is then..which of the nine pins of the db9 are used...

thanks in advance

a-

[Jeff-Birt]

totally stupid that the company ships these substandard wires...

I agree but cheap stuff sells...

You can find the user's manual with wiring info from Gecko's site: G540 4-Axis Motor Control.

[argon blade]

I agree but cheap stuff sells...

You can find the user's manual with wiring info from Gecko's site: G540 4-Axis Motor Control.

thanks tons!
according to page 5 all 9 pins are used...did you have to use a 9core wire when you built yours?

i have been to frys and the apex looks like i will be making my own as well

[Jeff-Birt]

You only need four wires to run to the stepper (pins 6, 7, 8, 9). Pins 1&5 are for the current programming resistor and the remaining one are just connected to DC Common for a shield drain.

I use a 20 AWG 4 conductor shielded cable to build my cables. (Google EZ-G540)...

[argon blade]

You only need four wires to run to the stepper (pins 6, 7, 8, 9). Pins 1&5 are for the current programming resistor and the remaining one are just connected to DC Common for a shield drain.

I use a 20 AWG 4 conductor shielded cable to build my cables. (Google EZ-G540)...

right on !!! i kinda figure that since there are only four wires coming from the stepper motors. but i was not sure which of the commons were important. that ex-g540 looks sweet!! but i already got db9 ends and housings. maybe later if this set up is less than statisfactory...jeff thanks 1000000's for the info!!!

[argon blade]

wow what a pain !!!

[Fastest1]

It wont take but an hour or so to solder all the connections for the 3 cables.

[rowbare]

Argon,

Please do not edit your posts and remove all of the contents. This makes the thread useless for people who have similar problems in the future. The whole idea behind a forum is that they become a repository of knowledge.

This is now a thread about nothing and is a waste of bytes. I am glad you got your answers but you have left nothing behind for anyone else to benefit from.

bob

[argon blade]

Argon,

Please do not edit your posts and remove all of the contents. This makes the thread useless for people who have similar problems in the future. The whole idea behind a forum is that they become a repository of knowledge.

This is now a thread about nothing and is a waste of bytes. I am glad you got your answers but you have left nothing behind for anyone else to benefit from.

bob

i totally agree!! i believe i accidently edited the wrong post...
let me try and fix it....jeff gave me some great information . i would hope that it would be avaibile for others with the same issue
i have contacted the seller and he seems willing to make right and send me some bigger cables...its a new toy and the honeymoon is not over...i really dont want to deal with voided warrenty issues..

[argon blade]

bummer it wont let me fix post #1
im sorry guys...

basically it went like this.....

i just got my taig / gekco 540
the wires that the motors came with are getting way too hot! like 190'
i was wondering if i was the only one with this problem and if any one else had solved the problem

my last post yesterday was kinda dumb and had just rehashed a different question...somewhere
in the process of logging on and editing ( so i didnt look like an idoit) i deleted the original post by accident...( so i guess i am an idiot)
=/

[argon blade]

as i expected melt down took place at 175' f / 80'c
after only running 425 lines of code the wires went as high as 190'f/
and began fusing....

i had i not been here or other wise distracted my home may have caught fire!!!

granted this is cutting air...no metal was harmed during this meltdown!!

this is bad!

my concern now it that by building my own wires i am:

a: just pushing the problem inside the breakout box
b: voiding my warrenty

thoughts suggestions?

A-

[fretsman]

I think at this point you should look at your controller and post as much information about it with pictures so the gurus here can help you figure what may be the issue.

Dave

[Jeff-Birt]

as i expected melt down took place at 175' f / 80'c
after only running 425 lines of code the wires went as high as 190'f/
and began fusing....

It really makes me wonder about some companies. How many other folks got stuck with crap lke this? Please post pics as Dave mentioned.

[noisillator]

my concern now it that by building my own wires i am:

a: just pushing the problem inside the breakout box
b: voiding my warrenty

No, you're only removing the resistance of the small-gauge wire they sent you from the system. I don't know who you bought the system from, but I'll bet they don't directly warranty the controller anyway (and maybe not the motors, either). My advice is to just fix it like Jeff suggested. That's how mine is wired - DB9 connectors from Fry's and 18 gauge stranded wire inside plastic wire looms running to the controller/power supply. The only thing I did different was to attach a small 12V fan to each stepper to cool them down.

[argon blade]

No, you're only removing the resistance of the small-gauge wire they sent you from the system. I don't know who you bought the system from, but I'll bet they don't directly warranty the controller anyway (and maybe not the motors, either). My advice is to just fix it like Jeff suggested. That's how mine is wired - DB9 connectors from Fry's and 18 gauge stranded wire inside plastic wire looms running to the controller/power supply. The only thing I did different was to attach a small 12V fan to each stepper to cool them down.

that is sound advice. i have contacted the seller and he has agreed to replace the cables with better ones. i would love to see pics of your fan setup

i have a question about limit switches.

is it only possible to set up home switches with the gekco 540?
im not sure there are enough inputs to allow two switches per axises...

thoughts?

[Fastest1]

You can share all of the limit switches and home switches on the same pin (wired in series). The only negative is that only 1 axis will home at a time. Still accurate and it would just take a few more moments to home. Or a second parallel port if you need more inputs.

that is sound advice. i have contacted the seller and he has agreed to replace the cables with better ones. i would love to see pics of your fan setup

i have a question about limit switches.

is it only possible to set up home switches with the gekco 540?
im not sure there are enough inputs to allow two switches per axises...

thoughts?

[strohkirchw]

Isn't better to do Home switches on Pin 1,2,3 and all limit switches wired in series to Pin 4?

[argon blade]

Isn't better to do Home switches on Pin 1,2,3 and all limit switches wired in series to Pin 4?

that sounds like a good solution
ill have to try it in the am

update the new wires got here
and really they dont look promising at all
22awg is not going to cut it
the new wires are smaller than the first batch
i got a feeling we are headed to burn:30 all over again

below are pics of the original wire, the new ones he sent , and the ones im gona have to finish now using jeff's db9 ends. i m bummed cuz my new machine is a POS for at least another week!!!!!

this retailer seems to have a good name so i am being reluctant to put him on blast ...but if these wire short out im calling it out!! and buying everything from jeff from here on out....

cuz so far i got a 1800$ paper weight and im not happy!!

stand by for results!!!