Error on Startup

[JerryFlyGuy]

I'm trying to do a test run [first time] on the spindle on my mill and keep getting an error code.

The VFD is a Hitachi SJ200 -022nfu

The spindle is a SC-73 Ekstrom rated at 2.8hp.

I've got the VFD connected to 240vac single phase.

I have a rated reactor which I've connected to the motor outputs and there after to the motor.

I'm following through the book to just get the motor running initially. I set the max and base Hz [120/300Hz]for the motor as well as the rated voltage [220vac] and amperage [8.8A] and set it up for keypad/pot control.

When I start the motor it rolls up to about 7.8Hz [with the reactor connected] or 7.1Hz [without the reactor connected] and faults at 11-11.8 amp. And over 300volts. There is a very high pitch squeal from the VFD for about 1/2 sec when I first turn the pot to start the motor [after hitting the run button] the motor starts out spinning and makes maybe a couple rev's [just gets started turning and it faults and slows back to a stop]

The error I get is a E 02. Now E 02 is a DECELERATION error.. while I'm trying to accelerate the motor.. can anyone make sense of this? I bought this VFD, the spindle and the reactor second hand but "as new". Does it sound like there is an issue w/ the VFD?

I get this error w/ or w/out the reactor connected. The spindle is very free to turn.. [nothing connected] and with a simple twist of the spindle I can spin it very easily.. there is no resistance to turning that I can feel..

I'm no expert [or even really experianced] with VFD's so any help that can be offered would be GREATLY appreciated..

Thnks..

[Al_The_Man]

Did you see the similar thread by Denis? http://cnczone.com/forums/showthread.php?t=38621
Apparently, there is a problem getting high freq Spindles with these VFD's?
It does not appear to make much sense to me.
I mentioned to him to try 60hz and run at that, see if you can do this.
Al.

[JerryFlyGuy]

I read it over but it seem's a bit different in that his didn't fault but just wouldn't go over 5Hz..

I'll try a lower Hz level, I can see the speed spooling up, but once it hit's 7.8Hz it just faults, also the current AND the voltage levels are off the charts.. I don't understand it myself.. doesn't make sense unless the VFD was fried when I bought it? How hard is it to send one of these away to get serviced in Canada?

Thanks Al

[Al_The_Man]

Do you have a small 240v 3 ph motor you can test the VFD with?
Al.

[JerryFlyGuy]

Nope, all I have is this spindle motor.. I tried it at 60Hz and now it only got to about 2.3hz before it crapped out.. I noticed on Hitachi's website that a E 02 error could mean there is a short... which would make sense, I saw a couple error's where it was indicating over 12amp's... the VFD is only rated for 11 soo.. Very frustrating... I may just call the service center in Vancouver to ask them about it on monday.. I don't know what else to check.. I pulled the motor cover off again to double check that the wires are all still connected and not shorted. The only other thing I can think of is that I've got a fourth wire [ground wire] attached to the body of the spindle [on a bolt that had a ground symbol on it] and this is grounded to the case of the VFD.. but that shouldn't do it [short it] should it? Would it hurt to pull that wire off and try running it w/out it connected?

[Al_The_Man]

The ground connection should not matter, If there is no short in the VFD it should run up to set frequency with no motor connected without error.
Al.

[JerryFlyGuy]

Ya I figured.. I disconnected it and tried it again.. but still the same thing..

I sure hope I didn't buy a Dudd VFD...

Sigh....

[Al_The_Man]

Doesn't sound right if nothing connected on the output.

[JerryFlyGuy]

Hrrm... well I didn't try it with the motor disconnected.. is that 'Ok' to do? I thought it might hurt something so I didn't try that.. I just disconnected the ground wire from the body of the spindle.. but If I can test it with the motor disconnected and not have to worry about hurting the drive I'll try that too..

[Al_The_Man]

Originally Posted by JerryFlyGuy Hrrm... well I didn't try it with the motor disconnected.. is that 'Ok' to do?

I have done it many times, just to set up parameters.
Al.

[JerryFlyGuy]

Ok.. I'll be back in 10 to tell you what happens when I do it....

[JerryFlyGuy]

Verdict is .. I don't think the issue is w/ the VFD.. w/out the wiring connected it will cycle up no problem.. but re-connect the wiring and it gives the E 02. I'm running it direct wired to the motor and the squeal [more like a squeek really but it's so short it's hard to get a feel for it] is coming from the spindle.. as far as I can tell. Yet the spindle doesn't make a sound when turned by hand.. it doesn't make sense.. It sounds like a metal on metal pivot or something that is a bit rusty.. maybe a hinge.. but the drive faults sooo fast that it only lasts for well ... less than a second anyway..

The motor should be absolutly silent shouldn't it?

I double checked and the U/V/W wires are connected correctly to the VFD.. I've also reset all the parameters to the default USA settings and re-programed the basic parameters.. it still does it..

Any other ideas?

It's supposed to be a two pole motor.. so I've got it set as such.. but is it possible it's a four pole or something? Would it hurt to try running it as a four or six pole?