Just thought of something else to check. Is there a parameter in the inverter that sets how quickly the inverter accelerates to the required frequency. It may be accelerating too quickly for the spindle to keep up.
Last edited by bushwakka; 01-17-2013 at 03:46 AM.
Reason: changed content
Thanks to Mactec54, I've found the problem and it came down to a single setting on the inverter.
A003 – spindle base frequency was set to 50Hz and changing it to 400Hz fixed the problem. This is despite the manual suggesting that this 'base' value should be set to 50Hz or 60Hz as shown in the picture below. Hence setting the max frequency to 400 Hz (A004) wasn't enough and required the A003 base frequency to be set to this value as well.
So I'm very relieved, but a little fustrated that I wasted a number of hours of testing and pulling down the spindle.
I'm using a Gecko G540 controller and have been able to use the 0-10v analog output to control the speed successfully on the inverter. However I'm keen to also control run/stop and can't figure out how to wire one of the Gecko's output's to the WJ200's input terminals? Can someone help?
Worked it out. Just needed to wire one of the g540 outputs to a 48v relay. On the relay side, I ran one of the wires to the WJ-200 digital input 1 and the other to ground. Then set A002 to 1 which switched the RUN control to the digital input.
A002 – 02
A003 – 400Hz is Spindle base frequency
A061 – 400HZ
A062 – 0
A082 – 230V/240V
A152 – 400HZ
A153 – 0
A154 – 100
A155 - 00
B012 – 10 Amps of your spindle
H003 – 2.2 KW this is your spindle kw rating
H004 - 2 poles most of these spindles are only 2 pole
Just to reconfirm; these settings looks like for the X200 and not the WJ200?
As i am currently looking at the WJ200 Manual and A151/2/3 are all % 0 to 50% range.
Been trying to setup WJ200 with 300Hz 3KW (10A) Spindle and i am almost sure i am missing few settings. Anyone can post the minimum settings required to be changed for WJ200?!
Here are absolute minimum settings on the WJ-200 for my 400Hz 2.2kW spindle. It assumes that you are manually running the spindle from the control panel (ie not from an external source). Change the various max freqs back to 300Hz if this is the limit of your spindle.
1. Select the digital operator as the source of motor speed command (A001=02). Also set the run-time motor speed with F001 (say 400Hz).
2. Select the digital operator as the source of the RUN command (A002=02).
3. Set the motor base & max frequency (A003=400Hz, A004=400Hz) and AVR voltage of the motor (A082=240V).
4. Set the motor current for proper thermal protection (B012=your spindle's max rated current, mine is 9A).
5. Set the number of poles for the motor (H004=2).
Spindle should then power up when you hit the 'START' button. Don't forget to set the 'F001' starting frequency as the motor won't move without this.
Guess i need to open the Spindle and inspect it. It runs fine from 0 Hz to 45Hz, when i try to speed it up more, Error 30 (Only when the spindle connected); When trying the spindle on another VFD; it shows output is shorted after 10Hz.