1st Jun 2009, 01:33 PM #16
Water cooled 1.5kw Spindle
Hi Noel and co,
Before i wire anything and program the VFD, I would like to consolidate and verify what I understand I should be doing for my water cooled spindle.
Here is what I believe the wiring and VFD settings should be set too:
Input to VFD:
240V Active - R
240V Neutral - S
Ground - E
Output to Motor (use shielded cable BW VFD and Motor):
U - Pin1
V - Pin2
W - Pin3
Ground - Pin4 (Bolted to spindle case in some manner to provide good earth)
Change PD001 Source of Run Commands to '1'
Change PD005 Max operating frequency to 400hz
Change PD004 base frequency to 400hz
Change PD003 Main frequency to 400hz
Change PD006 Intermediate frequency to 2.5
Change PD008 max voltage to 220v
Change PD009 Intermediate voltage to 15v
Change PD010 Min voltage to 8
Change PD011 frequency lower limit to >100hz (120hz to start)
Change PD142 7 Amps
Change PD143 2
Change PD144 3000
Also attached is a wiring diagram that I received.
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1st Jun 2009, 06:03 PM #17
Hi Mike - glad to hear that you have received your spindle and VFD.
Looks like you are on the right track with your settings - everything you have set out looks correct - jut watch things when you first start it up, keep one hand on the spindle to check the temp - should be OK though - then if no smoke - then go man go!!!
1st Jun 2009, 06:54 PM #18
Thanks Noel for looking over the setting.
Just whacked those babies in (values) and now I need to fix the earth (lack of) and connector which got pulled apart during the water inlet fix.
Cross fingers i don't blow the crap out of the unit. I'm real good at letting the lightning out of stuff.
1st Jun 2009, 07:15 PM #19
I have read that I need to ground the case. Fine, I understand the safety behind this.
But then it seems that you should also use shielded cable which implies it it also tied to ground. Isn't the shielded cable enough tied to pin 4 of the motor, which is then connected to the case?
1st Jun 2009, 08:08 PM #20
IMHO I would not rely on the shielding for an earth.
You really need to run a proper earth wire to ground.
I have included asmall photo of the top of my spindle - it is a bit difficult to see, but basically, I have run an earth wire from the VFD eart, along with the other three wires up to the top of the spindle. What is difficult to see, is that I have then doubled a loop of bared earth wire down to and under the retaining collett on top of the wiring plug, then took it back up and earthed it ontp the top of the z-column (green wire).
hope this helps - I am REALLY respectful of electricity - it scares me - so maybe I have overdone it, but better safe than sorry.
The shielding on the cabling itself will only stop interference, not electric shock.
1st Jun 2009, 08:11 PM #21
Whoops - sorry - got carried away and forgot to add the photo.
1st Jun 2009, 10:00 PM #22
Thanks for the feedback and photo. I took you advise and I have used the 4th pin to earth it internally to the motor housing. For some reason they did not paint it, so it made it quite easy to solder to.
I will also add the earth to the unit elsewhere to make sure it is safe.
2nd Jun 2009, 08:14 AM #23
Anybody using brake resistors? I don't have my spindle/vfd yet but read thru the manual...twice, to get familiar with all the parameters. From a safety point of view I want to stop the spindle as fast as possible (also be good if i setup a ATC in the future) but I can find nothing on what size braking resistor you should use.
I'll have to check my assumptions with a sparky at work but this is what I'm guessing from the manual.
PD028 stopping frequency set to max would be 10hz (point at which the resistor is switched in? as long as PD030 is not zero)
PD030 braking time set to time it takes to stop spindle with largest bit (ie surfacing bit) say 1 sec
PD031 DC braking voltage set to max 20% would mean ? 220/5 or 44v not sure what the spindle rated voltage is.
Given that the motor is 2.2kw and assuming its 220v then thats a 10 amp draw max. Putting all that together ... looks like a 5ohm 500watt resitor... sounds a bit small.
By the sounds of stuff on the net, most VFD drives have a lookup table of resistor values depending on braking and load requirements.
Be good to have a definite value rather than experiment and let the magic smoke out of the box.
so has anybody boldly gone... and done this yet?
2nd Jun 2009, 01:17 PM #24
Maybe an email to the supplier can clarify this problem.
2nd Jun 2009, 02:15 PM #25
Bit off topic to that previously posed, but the Hitachi VFD looks the same as the HuanYang model.
Here is the schematic for it to interface to Mach3 for CNC control
2nd Jun 2009, 03:47 PM #26
That seems like a fair price for what is esentially a frequency to voltage converter (you could make up one yourself alot cheaper but wouldn't have a nice PCB). I havent looked into spindle control much yet but wonder why using a step pulse is a good way to go. On the plus side if mach stops pulsing your spindle stops (if setup that way) but on the down side its another pulsing signal that mach has to manage.. plus noise etc etc. It would be nice if you can just talk directly to the VFD and "set and forget" the speed required at start of the job. I have no idea how you do this but guess its with modbus, macros and magic.
I assume you don't change spindle speed alot during a job, only at tool changes or roughing versus finish passes maybe.
More things to study....
2nd Jun 2009, 04:32 PM #27
2nd Jun 2009, 07:26 PM #28
Having trouble getting my unit going.
It's all wired up and I have used the settings i set out in the above post.
Turn on unit. It sits there flashing F100.00.
I try to increase the revolutions, hit start, etc and nothing happens at all.
2nd Jun 2009, 07:51 PM #29
Actually don't worry worked it out.
PD001 = 1 caused the issue. Set it to 0 and could use the front panel.
So this now coonfuses me. Does this run a trim pot or something?
2nd Jun 2009, 07:59 PM #30
mike - glad you worked it out.
It really shouldn't matter too much if pd001 is set to 1 or 0 (at least it makes no difference on mine) but if 0 works, then go with that.
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