How to connect motor cables to stepper motors:
http://crevicereamer.com/Page_4.html

How to solder up G540 motor cables:
http://crevicereamer.com/Page_4.html

DOWNLOADING G540B.XML:

$249 G540   Yeah, I know it's a 4 axis controller. But it's also the BEST and it's plug & play.
Anything else good will cost nearly as much without the benefits. Think of it as a really good BOB with 2 free $69 spare drivers.
$098 2 $49 KL23H2100-35-4B 381 oz motors for X, & Z
$050 One KL-300-48 48V/5A or $60 one KL-350-48 48V/7.3A power supply.
$010 Estop switch
$005 2 Home switches
$009 Straight thru parallel computer cable.
-----
$421 Total electronics cost.

$149 Mach3 discount cost with above purchase.

$570 To spend at Keling. http://kelinginc.net/


Start by reading this:

http://crevicereamer.com/Page_2.html

You may also need some other stuff:

You can use THIS wire for motor cables and home/limit switches. Ground the drain wire ONLY at the driver end. (DB9 Pins 2,3,4 for motors, PSU Ground for homes/limits)

http://cgi.ebay.com/Stepper-Motor-Wire-by-the-foot-2-individ-shielded-CNC_W0QQitemZ300324182374QQcmdZViewItemQQptZLH_DefaultDomain_0?hash=item45ecb75966

It also comes in 100 ft roll.

BELDEN 8723-100 STEPPER MOTOR CABLE WIRE

$32 http://www.fullcompass.com/product/305455.html 3 WK SHP

$33? http://www.jameco.com/Jameco/catalogs/c273/P101.pdf

$38 http://www.mcmelectronics.com/product/BELDEN-8723-060100-/36F1033WA

$39 http://www.jameco.com/webapp/wcs/stores/servlet/ProductDisplay?langId=-1&storeId=10001&catalogId=10001&productId=734180

$40 http://www.markertek.com/Product.asp?cat=CABLESCONN&subcat=BULKCABLE&prodclass=AUDIOBULK&baseitem=BL%2D8723%2D100&search=0&off=0&showreturn=0&utm_source=&utm_medium=&utm_term=&utm_content=&utm_campaign=

$44 http://www.alliedelec.com/Search/ProductDetail.aspx?SKU=2161456&MPN=8723+060100&R=2161456&SEARCH=2161456&DESC=8723+060100

EUROPE http://www.cable-world.co.uk/online.html


You won't need any db9 motor connectors with the G540, as they come WITH it. The G540 also has circuitry for simple spindle speed control and outputs for dc relays to turn coolant pump (Or router motor) on or off.

These inexpensive 48V relays are very good for starting and stopping spindle motor, cooling pump, vacuum etc.:

http://www.newark.com/tyco-electronics-potter-brumfield/t9ap1d52-48/power-relay/dp/66F6698

Unless you have the new G540EZ (Which adjusts current limit with trim pots) you will need one of THESE 1/4 Watt 3.48K resistors for each 381 or 387:

3.48KXBK-ND
http://search.digikey.com/scripts/DkSearch/dksus.dll?lang=en&site=US&WT.z_homepage_link=hp_go_button&KeyWords=3.48KXBK-ND&x=15&y=19

They only come in a pack of five, so about $1 for 10. With shipping it's about $3.50

While you are ordering from Digikey, might as well also get some spare F2318-ND G540 fuses:
http://search.digikey.com/scripts/DkSearch/dksus.dll?lang=en&site=US&WT.z_homepage_link=hp_go_button&KeyWords=f2318-nd&x=21&y=24


http://digikey.com/

Or, in Canada:

http://digikey.ca/

You will also need an estop switch, Home/limit switches and a 6 foot "straight thru parallel port cable. These are all available from Keling:

http://kelinginc.net/CNCPackage.html

The G540 is so small that many are mounting theirs INSIDE the computer case.

Camtronics has a case MADE for the G540:

http://s120220635.onlinehome.us/stepper-components.asp

Keling sells a controller box with G540 already installed:

http://kelinginc.net/ControlSystem.html

CR.