I may have figured out the issue..  I took for granted that the  
stepconf wizard would put the right values in for the step timing.   
The values that come up as a default when you select a G540 device are  
wrong.

What should the Step Time, Step Space, Direction Hold, and Direction  
setup be for a Gecko G540?

I happened upon the settings of:

Step Time: 2000
Step Space: 2000
Direction hold: 1000
Direction Setup: 1000

These SEEM to work. Is there something better/optimized for the G540?

Thanks,

Michael

On Dec 5, 2009, at 11:58 AM, Michael Jones wrote:

> Last night I finished the wiring phase of my project of replacing the
> old Chopper Drivers and Vexa steppers on a D&M4S mini mill with a
> Gecko G540 and KL23H284-35-4B stepper for the Z axis and 2
> KL23H276-28-4B steppers for the X and Y axis.
>
> EMC picked everything up quite nicely - I still have to sort out the
> charge pump.. but that's just details..  I'm quite impressed with the
> G540 and the new steppers.. they move FAST and QUIET.  The previous
> incarnation of the system was moving at a top speed of about 9ipm for
> cutting and maybe as fast as 15ipm for rapids (and that was on a good
> day)  The new system is running up to 60ipm for rapids!
>
> All went VERY well with a couple of minor issues:
>
> 1) Moving fast is not an issue..going slow is.   I haven't completely
> narrowed down where it starts having issues.. but it's around 5-10  
> ipm.
>
>       (Kind of off topic for this group.. but.. I'll throw it out there
> anyway)
>
> 2) In the previous incarnation I was using a Campbell break out board
> with the old chopper drivers and a 4 channel solid state relay to
> control the spindle on/off (with plans for some other things like
> vacuum pump and swarf-sucker)  The Gecko 540 looks like it grounds the
> output channel instead of sending a + signal to the output channel.
> My Relay has only 1 ground, and 4 inputs.  Is there a realistic way
> that I can control this relay or do I need to just go get a couple of
> single channel relays and rework it?
>
> Any ideas would be appreciated.
>
> Thanks,
>
> Michael
>
>
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