Electronics puzzle

**PsychoPig7** · 8th January 2014, 09:21 AM

Hi Guys

Here is a real puzzler for the 'electronic gurus' on this forum - I really hope you can help with this.

I have been running a Huanyang HY01D523B VFD and 1.5kw air-cooled spindle for some years, and all has been well apart from burning out one spindle, which I subsequently replaced.

Now I am having a specific issue.

First - the spindle and VFd are NOT connected in any way to Mach3. However - the problem - whenever I now press the start or the stop button on the VFD, I get an E-Stop in Mach3.

If I press the start button I get the E-Stop but the spindle runs. If I then reset Mach3 I can go ahead and cut - however, when I then press Stop on the VFd at the end of the cut, it again brings about an E-Stop in Mach3 but stops the spindle. Very annoying and unreliable.

I suspected 'noise', but everything is well earthed/shielded, etc, and has been running for several years.

Then thought about faulty buttons on the VFD controller panel, but doubt that both Start and Stop buttons would go simultaneously.

Changed over spindles (have a second one) and get the same results - so don't think it is the spindle. (Spindles run and start and stop OK without Mach3 running - conversely, Mach 3 runs a program and moves correctly without the VFD/spindle running, so I doubt that it is Mach3).

Also get the fault if I completely disconnect the cabling from the VFD to the spindle.

To reiterate - Mach3 and the VFD/spindle are NOT connected in any way, so I think it must be either 'noise', but have done a great deal to rule this out, and the only thing I can think might be happening is some 'glitch' within the VFD Start/Stop system which then produces 'noise'?????

I do have another VFD which I could try - this is a Powertran PI8600 but I am unsure how to set it up as it has a different system to the PID's that Huanyang use (much more complicated it seems).

Thoughts please - if anyone with knowledge of electronics has any ideas they would be warmly welcomed.

Cheers

Noel

**Bob Willson** · 8th January 2014, 11:14 AM

Hi Noel

Not that I have any expertise in the electronics side of things, but are you sure that the earth side of the VFD isn't connected to the rest of the tables circuitry?

So, if you bring in another power circuit to supply the power to the VFD (say an extension cord from your kitchen) does it still blow?

If it does, then I have used up all the things that I can think of.

**rodm** · 8th January 2014, 11:29 AM

Hi Noel,
Logically from what you have described there is a problem with the VFD. Noise is the likely cause but before you go chasing down the invisible monster try running a separate 240 lead to the VFD and put it in a different power point to the one running your machine.

Bob - you beat me by that much.

**PsychoPig7** · 8th January 2014, 01:47 PM

Originally Posted by Bob Willson

Hi Noel

Not that I have any expertise in the electronics side of things, but are you sure that the earth side of the VFD isn't connected to the rest of the tables circuitry?

So, if you bring in another power circuit to supply the power to the VFD (say an extension cord from your kitchen) does it still blow?

If it does, then I have used up all the things that I can think of.

Hi Bob
thanks for that - I will give it a go this afternoon and let you know.
Cheers
Noel

**PsychoPig7** · 8th January 2014, 03:11 PM

Bob, Rod - two of nature's gentlemen.

Tried what you both said.

I actually had the driver board, the VFD, the spindle, and the computer all running off the one 15amp socket and circuit, with both the power into the VFD and the Three-phase section, both earthed to the one point inside the VFD.
Duh

Left the computer and the driver board both on the 15amp circuit and shifted the VFD/spindle to a 10amp circuit, with separate earthing for both VFD power in, and three-phase/spindle.

Just did a dummy (how appropriate) run, and the issue appears to have gone away.

I will try a serious cut tomorrow, but am very hopeful that this might fix matters. Phew!!!

Thanks again gentlemen.

Rod - on a separate matter - I think you have a 1.5kw Fuling VFD which you used to power your 1.5kw air-cooled spindle some time ago??? - I believe this is very similar to my new Powtran VFD and was wondering if you could post your settings please - I find the new VFD a bit more complicated to program - but that is probably just me.

Cheers Guys

Noel

**Bob Willson** · 8th January 2014, 07:31 PM

Glad it worked Noel.

Originally Posted by rodm

Bob - you beat me by that much.

Hi Rod

I think you will find that now you are retired, that this will happen with increasing frequency. Not just me, but the world in general.

**rodm** · 9th January 2014, 12:32 AM

Originally Posted by Bob Willson

Hi Rod

I think you will find that now you are retired, that this will happen with increasing frequency. Not just me, but the world in general.

I think you are right Bob.

Hi Noel,
There are only 25 parameters for the Fuling VFD. An electronics engineer set mine up and it works well so I haven't changed anything. It was originally running an 800watt spindle but I swapped that for a 1.5kw when the bearing were shot. I didn't change any of the parameters and it still worked. Note there are no setting for amps as I think it does that itself.
Here are the setting and mine has an analogue pot on the front for speed control.
F00 01
F01 400
F02 220
F03 110
F04 400
F05 400
F06 20
F07 10
F08 20
F09 10
F10 10
F11 10
F12 50
F13 00
F14 00
F15 01
F16 01
F17 01
F18 00
F19 to F25 0.0
Not sure if it is going to help you.
cheers,
Rod

**PsychoPig7** · 14th January 2014, 09:37 AM

Thanks Rod
Will give it a go.
noel

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