HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

[shaffin]

Hello,

When powering up and running the spindle for about 30s, its runs so very hot that you cant keep you hand over the spindle for a couple seconds! The spindle is rated for 8A and the VFD is rate at 10A. There is something I dont have correct as it seems the spindle is being electrically overloaded!

I have gone through 2 VFDs now thinking that my VFD was defective but I get the same result so its definitely something I am doing wrong!



VFD Info

I have attached the VFD manual but it can also be seen online.

Nowforever ES100S2R2 VFD link to manual: https://www.shopmasterusa.com/wp-con...NUAL-E-100.pdf



VFD Settings:

P0-000 = 0 [Select command source - set to keyboard control]

P0-001 = 0 [Select frequency source - set to main frequency]

P0-002 = 0 [Main frequency source - set to keyboard potentiometer]

P0-003 = 0 [Assistant frequency source - set to keyboard potentiometer]

P0-004 = 400 [Keyboard digital setting frequency]

P0-005 = 5 [Jog frequency]

P0-006 = 1 [Running direction - set to 1 to run the spindle clockwise]

P0-007 = 400 [Upper frequency]

P0-008 = 0 [Lower frequency]

P0-009 = 8 [Accelerate speed time]

P0-010 = 8 [Decelerate speed time]

P0-011 = 6 [Carrier frequency]

P0-012 = 1 [V/F curve setting - set to 50Hz motor, general load]

P0-013 = 3 [Torque boost]

P0-014 = 100 [Automatic torque compensation gain]

P0-015 = 100 [Automatic slip compensation gain]

P0-031 = 0 [Stop mode]

P0-035 = 80 [Protection current of motor overload - set to 80% of VFD rated amps as motor is rated for 8A]

P0-036 = 150 [Over-current protection value when losing steps]

P0-037 = 130 [Over-voltage protection value when losing speed]



Spindle Info

Spindle being used is a GDZ-80F-2.2KW Air-Cooled Spindle



Wiring Info

Spindle: [Pin1 -> U], [Pin2 -> V], [Pin3 -> W], [Pin4 -> E]

240VAC Power: [Black -> R], [White -> S], [Green -> E]

Any help or feedback provided is much appreciated!
Sam.

Similar Threads:

• Need help! Spindle Alarm 750 : Spindle Serial Link Error
• torq cut spindle, need to run cnc with out spindle running
• KM-3P - MOTION ERROR only when the spindle is running in a program
• Problem- mach3 spindle dro not working, spindle speed changing while jogging and running code
• Spindle not Running

[mactec54]

Hello,

When powering up and running the spindle for about 30s, its runs so very hot that you cant keep you hand over the spindle for a couple seconds! The spindle is rated for 8A and the VFD is rate at 10A. There is something I dont have correct as it seems the spindle is being electrically overloaded!

I have gone through 2 VFDs now thinking that my VFD was defective but I get the same result so its definitely something I am doing wrong!



VFD Info

I have attached the VFD manual but it can also be seen online.

Nowforever ES100S2R2 VFD link to manual: https://www.shopmasterusa.com/wp-con...NUAL-E-100.pdf



VFD Settings:

P0-000 = 0 [Select command source - set to keyboard control]

P0-001 = 0 [Select frequency source - set to main frequency]

P0-002 = 0 [Main frequency source - set to keyboard potentiometer]

P0-003 = 0 [Assistant frequency source - set to keyboard potentiometer]

P0-004 = 400 [Keyboard digital setting frequency]

P0-005 = 5 [Jog frequency]

P0-006 = 1 [Running direction - set to 1 to run the spindle clockwise]

P0-007 = 400 [Upper frequency]

P0-008 = 0 [Lower frequency]

P0-009 = 8 [Accelerate speed time]

P0-010 = 8 [Decelerate speed time]

P0-011 = 6 [Carrier frequency]

P0-012 = 1 [V/F curve setting - set to 50Hz motor, general load]

P0-013 = 3 [Torque boost]

P0-014 = 100 [Automatic torque compensation gain]

P0-015 = 100 [Automatic slip compensation gain]

P0-031 = 0 [Stop mode]

P0-035 = 80 [Protection current of motor overload - set to 80% of VFD rated amps as motor is rated for 8A]

P0-036 = 150 [Over-current protection value when losing steps]

P0-037 = 130 [Over-voltage protection value when losing speed]



Spindle Info

Spindle being used is a GDZ-80F-2.2KW Air-Cooled Spindle



Wiring Info

Spindle: [Pin1 -> U], [Pin2 -> V], [Pin3 -> W], [Pin4 -> E]

240VAC Power: [Black -> R], [White -> S], [Green -> E]

Any help or feedback provided is much appreciated!
Sam.

You may have to do Reset and then just reset these Parameters in this list which is almost the same as what you have, with a few extra ones

Have you checked the continuity between the Pin 4 and the spindle body, this is not what is causing your over heating problem but must be checked, and corrected it is open, are you using shielded cable between the VFD and the spindle

Now Forever VFD Drive Parameters
Mactec54
P0-000=1 ( 1 For Analog Control 0 For Key Board Control )

P0-001=0

P0-002=1

P0-04=400

P0-006=2

P0-007=400

P0-008=100

P0-009=8 (Adjustable )

P0-010=8 (adjustable )

P0=011=8

P0-012=1

P0-024=400

P0-030=1

P0-036=100%

P0-037=100%

d1-003=?? ( VFD Rated Power )

d1-004=?? ( VFD Rated Voltage )

d1-005=?? ( VFD Rated Amps )

d2-001=400

d2-002=400

d2-003=?? ( VFD Output Amps )

d2-004=220

d2-005=339 ( This is calculated using 240v if your voltage is higher than this I will have to give you a different number do you know your supply Voltage= ??

You may not be able to set any of the d1 and d2 Parameters some are read only and auto ranging

[mactec54]

Hello,

When powering up and running the spindle for about 30s, its runs so very hot that you cant keep you hand over the spindle for a couple seconds! The spindle is rated for 8A and the VFD is rate at 10A. There is something I dont have correct as it seems the spindle is being electrically overloaded!

I have gone through 2 VFDs now thinking that my VFD was defective but I get the same result so its definitely something I am doing wrong


Any help or feedback provided is much appreciated!
Sam.

I did not ask how slow have you been running it you most likely have a minimum speed of 12,000 RPM

Is your spindle 24,000 RPM or 18,000RPM there is a big difference for the main Parameters so what are your spindle Spec's

Voltage=220
Amps=
Hz=
RPM=

[Eldon_Joh]

i find nowhere in that manual an option for setting the output minimum and maximum voltage.

you have 6 options for the volts/hz curve, 50, or 60hz. P0-012=1




as such what i think you will find with that VFD is that it will output the maximum voltage for any frequency above 50 or 60hz. this is why the motor is burning up at low speeds. you can verify this with 2 120vac lightbulbs in series across any two outputs of the vfd. (unless you have a 220vac lightbulb handy?) verify that they light up only dimply at 50hz. full brightness at 400hz.


depending on how efficient your spindle motor is, you may burn it up at anything less than about 3/4th's the rated speed because the vfd is delivering 220vac regardless what the output frequency is if its above 50 or 60 hz. but technically you could try and use the spindle with that inverter if you only use it at full speed or a sufficient fraction of full speed to avoid over current problems.

[shaffin]

The spindle spec is as follows:

Voltage=220
Amps=8
Hz=400
RPM=24000

[shaffin]

I did set the parameters as you suggested, and after about 90s of running almost burnt my hand when placed over the spindle :-(

These are the readings I found:

d1-003=2.2 ( VFD Rated Power )

d1-004=220 ( VFD Rated Voltage )

d1-005=10 ( VFD Rated Amps )

d2-001=400

d2-002=62.20... (this reading was rising but i had to shut it down because the spindle was too hot)

d2-003=10.6 ( VFD Output Amps )

d2-004=35.1... (this reading was rising but i had to shut it down because the spindle was too hot)

d2-005=328

[shaffin]

i find nowhere in that manual an option for setting the output minimum and maximum voltage.

you have 6 options for the volts/hz curve, 50, or 60hz. P0-012=1




as such what i think you will find with that VFD is that it will output the maximum voltage for any frequency above 50 or 60hz. this is why the motor is burning up at low speeds. you can verify this with 2 120vac lightbulbs in series across any two outputs of the vfd. (unless you have a 220vac lightbulb handy?) verify that they light up only dimply at 50hz. full brightness at 400hz.


depending on how efficient your spindle motor is, you may burn it up at anything less than about 3/4th's the rated speed because the vfd is delivering 220vac regardless what the output frequency is if its above 50 or 60 hz. but technically you could try and use the spindle with that inverter if you only use it at full speed or a sufficient fraction of full speed to avoid over current problems.

I dont have any 220v bulbs to test with :-(

[mactec54]

The spindle spec is as follows:

Voltage=220
Amps=8
Hz=400
RPM=24000

The only change I would make to the Parameter list I posted is P0.008=200

This is only a safety as to how slow your spindle can run without cooking it's self

Have you checked the Grounding and wiring

[shaffin]

The only change I would make to the Parameter list I posted is P0.008=200

This is only a safety as to how slow your spindle can run without cooking it's self

Have you checked the Grounding and wiring

When I do a continuity test between Pin4 (on the spindle) and the spindle body - I get nothing.....

[mactec54]

I did set the parameters as you suggested, and after about 90s of running almost burnt my hand when placed over the spindle :-(

These are the readings I found:

d1-003=2.2 ( VFD Rated Power )

d1-004=220 ( VFD Rated Voltage )

d1-005=10 ( VFD Rated Amps )

d2-001=400

d2-002=62.20... (this reading was rising but i had to shut it down because the spindle was too hot)

d2-003=10.6 ( VFD Output Amps )

d2-004=35.1... (this reading was rising but i had to shut it down because the spindle was too hot)

d2-005=328

The Buss voltage looks ok d2-005=328

You have the parameters set correct, so I would say you have a problem with the spindle

[mactec54]

When I do a continuity test between Pin4 (on the spindle) and the spindle body - I get nothing.....

As I though you have no Ground connection to the spindle body this is important, most with these air-cooled spindles remove the plastic cap and cut a notch out of the cap where one of the screws go through the cap, just enough to make clearance for a Ground terminal to be attached at this point and then back up to the plug where you can solder the connection

[mactec54]

I dont have any 220v bulbs to test with :-(

And you don't need one

[mactec54]

i find nowhere in that manual an option for setting the output minimum and maximum voltage.

you have 6 options for the volts/hz curve, 50, or 60hz. P0-012=1




as such what i think you will find with that VFD is that it will output the maximum voltage for any frequency above 50 or 60hz. this is why the motor is burning up at low speeds. you can verify this with 2 120vac lightbulbs in series across any two outputs of the vfd. (unless you have a 220vac lightbulb handy?) verify that they light up only dimply at 50hz. full brightness at 400hz.


depending on how efficient your spindle motor is, you may burn it up at anything less than about 3/4th's the rated speed because the vfd is delivering 220vac regardless what the output frequency is if its above 50 or 60 hz. but technically you could try and use the spindle with that inverter if you only use it at full speed or a sufficient fraction of full speed to avoid over current problems.

Many have used this same VFD Drive, they have auto ranging for most of the Parameters as long as the main Parameters are set the VFD Drive is fine

[shaffin]

As I though you have no Ground connection to the spindle body this is important, most with these air-cooled spindles remove the plastic cap and cut a notch out of the cap where one of the screws go through the cap, just enough to make clearance for a Ground terminal to be attached at this point and then back up to the plug where you can solder the connection

So if I understand correctly, if I open up the plastic cap and trace through the inside of Pin4 and run a ground wire to the body of the spindle that should work?

[shaffin]

This is inside the cap!

[shaffin]

Just an update, tried to temporarily ground Pin4 to body but motor still burning up :-(

[mactec54]

Just an update, tried to temporarily ground Pin4 to body but motor still burning up :-(

The Ground won't stop the over heating, you would have to have the cap on for the air to cool the spindle though, check the air ways are clear while you have the cap off

[mactec54]

The spindle spec is as follows:

Voltage=220
Amps=8
Hz=400
RPM=24000

Another thought is that the spindle may be etched 220v with the wrong voltage on it could be a 110v rated spindle

Can you check the windings with a meter in ohms setting

Pin1 to Pin 2=

Pin2 to Pin3=

Pin3 to Pin 1=

[mactec54]

The Ground won't stop the over heating, you would have to have the cap on for the air to cool the spindle though, check the air ways are clear while you have the cap off

Change this Parameter also as you are in NA

P0-012=4