Diving Head First... Huanyang 220v VFD + Water Cooled Spindle Upgrade on my G540/Mach

[ericks]

Wow....where did the KISS practice go with all those wires...…... I expect they'll be bundled up neatly when the time comes.

On the subject of wire...….I just bought one of those auto wire stripping pliers on BANGGOOD for US$8.99......all these years I've been doing it the hard way and stripping back the insulation with a knife and side cutters...…..it's perfect....now they'll have to prise it out of my cold gnarled hand before I let it go.
Ian.

Must admit that even though i have two wire strippers, one at work and one at home i hardly ever use them

[handlewanker]

I couldn't resist the price.

[ericks]

The only difference with your tests would be Parameter settings your Sako has the same PWM output as any other VFD Drive The Sako Drive is also quite inexpensive and can be brought for less than the HY there are may choices for VFD Drives it just depends how much the user wants to spend

Oh no, again you prove that you really don't know much about drives or the technology that "drives" them. Maybe do a bit more google searches than usual mate

[ericks]

I couldn't resist the price.

I would like to see what it looks like

[handlewanker]

On EBAY as well under wire strippers....the ones with the yellow handles that strip and crimp too.....A$14.00....I got the BANGGOOD one in 3 days as it was probably a local stockist......having test used it for a hundred odd wire pieces I highly recommend it.....I'll see if I can post a pic.
Ian.

[mactec54]

Mactec54,

thank you very much!
i am using a double pole breaker at my panel. i am not sure if i should have a breaker at the VFD enclosure or that on/off switch would suffice.

still not quite 100% sure if i need a Neutral coming into the box. if the contactor coil voltage is 110-250VAC, can i just connect A2 from Contactor to the other RED hot leg?

thanks again

Al

You only need a Neutral if you are using 120v which is always good to have which can be used where needed, so if 120v is needed anywhere then yes add the neutral

The main Breaker should not be the only source for protection, if you used that only then you would not use a fuse in the feed to the VFD Drive

The On/Off switch can be a 2 Pole Breaker which you would have in your cabinet, this would serve both as protection and as a Switch

[mactec54]

Ok so follow-up question.

so i checked my basement again and i currently have L6-20 receptacle already installed.
so i've revised as followsAttachment 431076

changes made:

1) A2 on the Contactor connected to RED
2) Added CL-523Y Indicator Light to 4T2 and 6T3
Nominal Lamp Voltage:240 VAC
https://www.galco.com/buy/ABB/CL-523Y

3) eliminated Neutral inside the enclosure

4) added fuse to the other line

thanks!

Al

You should not use a Fuse in this case it wants to Be a 2 Pole Breaker then if there is a fault both lines supplying the VFD Drive will be cut at the same time

[kinghong1970]

You only need a Neutral if you are using 120v which is always good to have which can be used where needed, so if 120v is needed anywhere then yes add the neutral

The main Breaker should not be the only source for protection, if you used that only then you would not use a fuse in the feed to the VFD Drive

The On/Off switch can be a 2 Pole Breaker which you would have in your cabinet, this would serve both as protection and as a Switch

hahaha and i just PM'd you about this...
i do have a 120V receptacle in the area to power the PC and G540s... it comes from same panel but ran separate lines...
i was planning to use this

https://www.alliedelec.com/product/r...E&gclsrc=aw.ds

installed on the panel...

[mactec54]

hahaha and i just PM'd you about this...
i do have a 120V receptacle in the area to power the PC and G540s... it comes from same panel but ran separate lines...
i was planning to use this

https://www.alliedelec.com/product/r...E&gclsrc=aw.ds

installed on the panel...

Yes that is a good switch for Cabinet supply On/Off this is not a circuit protection though which you should have where your fuses are ( 2 Pole Breaker 25A max 30A ) Power Filter 30A TDK RSEN-2030L

[ericks]

On EBAY as well under wire strippers....the ones with the yellow handles that strip and crimp too.....A$14.00....I got the BANGGOOD one in 3 days as it was probably a local stockist......having test used it for a hundred odd wire pieces I highly recommend it.....I'll see if I can post a pic.
Ian.

Thanks for the image

[ericks]

hahaha and i just PM'd you about this...
i do have a 120V receptacle in the area to power the PC and G540s... it comes from same panel but ran separate lines...
i was planning to use this

https://www.alliedelec.com/product/r...E&gclsrc=aw.ds

installed on the panel...

Good choice of Isolator, i use the same one on my panels. Not bad for the price

[ericks]

Al, i was just wondering how you going with this?

[kinghong1970]

Al, i was just wondering how you going with this?

Ericks, i'm patiently awaiting parts...

received line filter:
https://www.digikey.com/product-deta...219-ND/7044342

getting rest of stuff by friday.

got the mock up mounted on a plywood to "test"

hoping to get some progress over the weekend.

thanks!

Al

[ericks]

Ericks, i'm patiently awaiting parts...

received line filter:
https://www.digikey.com/product-deta...219-ND/7044342

getting rest of stuff by friday.

got the mock up mounted on a plywood to "test"

hoping to get some progress over the weekend.

thanks!

Al

That is great. There are many options re parts to use. Finding the right combination can be a challenge. For sure doing it on plywood is a good idea. I usually also use scrap material to make sure everything fits

[kinghong1970]

yea, hindsight kinda sucks...

wanted a 8 3/4" deep enclosure for the stuff... figured bigger = better...
received a 20x20x8.75" enclosure... yea... too big...

getting a 12x16x8.75 enclosure today.
the HY VFD with the POT knob is a bit deep...

just received the MOM NO and MOM NC switches and the contactor... ABB feels much nicer than the amazon/china-zon ones...

lol at me... using cheap VFD/Spindle and expensive switches... ha!

[kinghong1970]

So minor update...

Created a mock up on a piece of plywood to test up to the EMI filter.

Please don't mind the messy wiring... this is just to see if it works...


Mounted the switches and indicator light (temporarily connected to the outputs of the EMI filter as indicator)


some Liquid Courage...


Voila, press GREEN then the contactor engages and LIGHT ON! woot!
red button disengages the contactor! WOOT!


had a minor issue... my previous wiring pretty much turned on the mini 12V PSU when i turned on the "isolator" AKA Red/Yellow thingy knob switchy...
so re-wiring such that the HOT for the PSU is connected to the un-used pole of the contactor as such...


so when the contactor is engaged, the 120mm Fan will power up and also thinking of connecting the 12V pump as well.

now to connect to VFD and get movement on the spindle.

Cheers!

Al

[mactec54]

So minor update...

Created a mock up on a piece of plywood to test up to the EMI filter.

Please don't mind the messy wiring... this is just to see if it works...


Mounted the switches and indicator light (temporarily connected to the outputs of the EMI filter as indicator)


some Liquid Courage...


Voila, press GREEN then the contactor engages and LIGHT ON! woot!
red button disengages the contactor! WOOT!


had a minor issue... my previous wiring pretty much turned on the mini 12V PSU when i turned on the "isolator" AKA Red/Yellow thingy knob switchy...
so re-wiring such that the HOT for the PSU is connected to the un-used pole of the contactor as such...


so when the contactor is engaged, the 120mm Fan will power up and also thinking of connecting the 12V pump as well.

now to connect to VFD and get movement on the spindle.

Cheers!

Al

Run the Filter Ground to the VFD Ground

For your spindle Shielded wire clamp, you can just use a 360 degree clamp attached to the Ground plane once you do your final install, keep the insolation ( outer jacket ) on as much of the Spindle Cable as possible and only expose as much wire as needed to make the connection

[kinghong1970]

Run the Filter Ground to the VFD Ground

For your spindle Shielded wire clamp, you can just use a 360 degree clamp attached to the Ground plane once you do your final install, keep the insolation ( outer jacket ) on as much of the Spindle Cable as possible and only expose as much wire as needed to make the connection

Thanks for that info!

Run the Filter Ground to the VFD Ground

ok, so you mean the filter GND terminal on the RIGHT hand side connect to the VFD Ground.
now, i took a multimeter and checked the two screws on the plastic body that has GND symbol on it... seems they're not connected to any ground and it's there to serve as a grounding point? so to run Filter GND to VFD GND, connect to the "E" terminal on VFD, correct?

For your spindle Shielded wire clamp, you can just use a 360 degree clamp attached to the Ground plane once you do your final install, keep the insolation ( outer jacket ) on as much of the Spindle Cable as possible and only expose as much wire as needed to make the connection

I was planning to use Cable Glands but even if i get something like this,
https://www.mcmaster.com/7802k24

i will have about 3" of exposed & unshielded wires inside the case from gland to VFD.

for the clamp method...
i found this at Allied...
https://www.alliedelec.com/product/k...8102/70183208/

applicable for my use to slide insulation off 1/2" and attach Spindle to Grounded Case using the above works?

[mactec54]

Thanks for that info!


ok, so you mean the filter GND terminal on the RIGHT hand side connect to the VFD Ground.
now, i took a multimeter and checked the two screws on the plastic body that has GND symbol on it... seems they're not connected to any ground and it's there to serve as a grounding point? so to run Filter GND to VFD GND, connect to the "E" terminal on VFD, correct?



I was planning to use Cable Glands but even if i get something like this,
https://www.mcmaster.com/7802k24

i will have about 3" of exposed & unshielded wires inside the case from gland to VFD.

for the clamp method...
i found this at Allied...
https://www.alliedelec.com/product/k...8102/70183208/

applicable for my use to slide insulation off 1/2" and attach Spindle to Grounded Case using the above works?

Cable Glands are good and it seems the one you have selected is EMI compliant

Yes that type of clamp works well as long as you can get the right size to clamp the cable Shield you are using

Diagram of your filter Grounding this is important

[kinghong1970]

Ok, placed order for the clamping style from Digikey.

https://www.digikey.com/product-deta...8102-ND/303956


and updated wiring diagram to make connection from FILTER GND to VFD GND

the clamp is will be attached to grounding plane (Case)