Need Help!- Please check my Spindle settings. I can't get Mach 3 to run my spindle

[TheProCreator]

Ok, I have Mach3 and a g540 connected with the R25 cable. I do not have any other boards or plugs (Smoothstepper, etc). My spindle is a 1.5kw with VFD. The spindle works perfectly in manual mode. When I change PD001 and PD002 settings to 2 Mach 3 will not run the spindle. I am certain that I am missing something in Mach 3 in the port/pin configuration. On my diagnostics I am getting a red led on enable 1,2, and 3. Any suggestions???

[jsantos]

Originally Posted by TheProCreator Ok, I have Mach3 and a g540 connected with the R25 cable. I do not have any other boards or plugs (Smoothstepper, etc). My spindle is a 1.5kw with VFD. The spindle works perfectly in manual mode. When I change PD001 and PD002 settings to 2 Mach 3 will not run the spindle. I am certain that I am missing something in Mach 3 in the port/pin configuration. On my diagnostics I am getting a red led on enable 1,2, and 3. Any suggestions???

How do you have your VFD connected to the G540? Normally, you would have the speed control connected to the G540 and a relay to turn your VFD on and off. The relay is in turn controlled by OUTPUT1 or OUTPUT2.

Download this and study the VFD connections. -> http://www.homanndesigns.com/EN010_V8.pdf

You do not need to set up the spindle in the pins and configurations either.

Once you've got your connections verified, I might be able to help you further with the Mach3 settings. I'll have to look at how I set mine up.

[TheProCreator]

Thanks for the reply. I have POS 7, 8, and 9 of the G540 MAIN TERMINAL BLOCK wired directly to the ACM, V1, and +10 terminals on the VFD respectively as on the attached PDF. My VFD uses a 220v converter and is powered on/off with a switch.

[jsantos]

Originally Posted by TheProCreator Thanks for the reply. I have POS 7, 8, and 9 of the G540 MAIN TERMINAL BLOCK wired directly to the ACM, V1, and +10 terminals on the VFD respectively as on the attached PDF. My VFD uses a 220v converter and is powered on/off with a switch.

When you say, it's powered on/off with a switch, do you mean that the VFD is powered on/off with a switch? Or do you mean you turn the spindle on/off with a switch?

The "Relay Control" under Spindle Setup is what turns the spindle on and off. In your set-up, you specified "Output1" as your "CW" (Forward) and "Output2" as your "CCW" (Reverse). But in your "Output Signals", you have not enabled "Output1" and "Output2".

Normally, "Output1" and "Output2" will turn on/off relays that are in turn connected to the FWD and REV terminals of your VFD. Do you have that setup?

In my case, I've got my "CW" and "CCW" specified as "Output1" as I don't want my spindle going in reverse. My "Output1" is enabled in the "Output Signals" and turns on a relay that's connected to the FWD terminal of my VFD.

BTW, you do need the "Spindle" setup in the "Motor Outputs" as that's the PWM. My Bad.

[TheProCreator]

I currently turn the VFD with a switch. I do not have any relays set up. Is it absolutely necessary to run the VFD with Mach3 with a relay?

[jsantos]

Originally Posted by TheProCreator I currently turn the VFD with a switch. I do not have any relays set up. Is it absolutely necessary to run the VFD with Mach3 with a relay?

You're actually not running (turning on/off) the VFD with a relay. You're turning the spindle on/off with a relay with Mach3. That's what the Relay Control in the spindle setup is for.

If your VFD is similar to mine in the sense that you turn on the spindle by shorting the FWD to CMN or REV to CMN, then yes you do need the relay. Look at the HommanDesign diagram to see how the Auxiliary Relay Output is connected to Output1 of the G540 and to the FWD of the VFD. If you want a reverse for your spindle, you'll have to have another relay connected to Output2 and to the REV of your VFD.

[jsantos]

I'm looking at the G540 manual and it looks like it might be possible to connect the VFD FWD to Output1 and the VFD CMN to the G540 ground, eliminating the need for a relay. But before I would do this, I'd ask Gecko. The Gecko forum might be a good place to ask.