The Card essentially provides the connection from the ShopBot software running on the PC to your own CNC tool or robotic device, via a USB interface. You can either wire this card up directly to your drives and other I/O, or you can connect it through one of several Interface Boards. These are the same cards that run all our current PRS tools and are the cards that current Version 4g's are fitted with. Rather than a 4g board, what I think you want for your project is one of our Control Cards.
(You could modify the 4g board and mount the Geckodrives off-board on heat sinks, but this would be more work than my suggestion below.) While the Geckos are rated to 80v, we've found over the years that the 60-70v range for the power supply is a little less likely to create problems than pushing the limit. So the heating issue and the power wiring of the Gecko's on the board are the reasons we recommend not running the drives at the higher currents on the 4g board. And, as it is, one needs to be careful to keep the Control Box cool with 4 Gecko's in them.
#G540 geckodrive driver
Geckodrive says to heatsink their driver over 3 amps. The disadvantage of this convenient driver mounting technique is that there is no heat-sinking of the Geckodrives (they do run warm) and the wiring is limited in current capacity by the traces on the board. This puts all the wiring on the board and keeps things simple - especially for ShopBot owners who are just swapping in a new 4g board. Because we also wanted a drop-in replacement that did not require people fussing with wiring-up drivers, we came up with a snap-in board mount for the Geckodrives on the board.
#G540 geckodrive drivers
The output on drivers for the Version 4g Interface Board is set to ~2A (and we power it in new boxes with 63V) because this provides a good match to motors on older ShopBots and motors on new tools.
Let me ramble a bit about some of your questions.
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