Hi guys,

I’ve been building my first CNC slowly over the course of this year and everything has been going pretty well overall, I’ve browsed CNC Zone regularly but haven’t really needed to post about anything before. However, more recently I’ve run into an issue when trying to run my spindle. I’ve got a Hitachi 2.2kW WJ200 and a Chinese 1.5kW spindle from solar.jean on eBay. I’ve wired the spindle into the VFD with a 4 core cable (not completely sure of gauge). Here are pictures of these:

Attachment 262134
Attachment 262136

I originally followed the WJ200 manual to setup the VFD by setting the four basic parameters of base frequency (400 Hz), AVR voltage of 220V, number of poles (2), and the motor current limit to 5A, all based on the motor nameplate. The first time I ran the motor, it started up and accelerated to 400Hz seemingly fine, but after about 20 seconds the VFD tripped an overload protection error (E05.3). The WJ200 manual says: “E05 - Overload protection - When a motor overload is detected by the electronic thermal function, the inverter trips and turns OFF its output”, and the .3 means the trip occurred at constant speed.

I downloaded Hitachi control software (ProDrive Next) which lets you plug into the VFD via USB, and this was the output from startup of the spindle until it trips:

Attachment 262138

This shows the input to the VFD from mains, the current draw is only 2A at 250V (this is in Australia, which is why it's ~240V).

Attachment 262140

Do these numbers make sense? Does anyone have any suggestions as to what I can look closer at? I’m not sure how to debug this short of buying a new spindle/new VFD to see what works. Is there any testing/inspection I can do on the WJ200 or the spindle to figure out why it is drawing over the FLA with zero load?

If anymore information would help, let me know.

Cheers!