[mactec54]

I would love to find out what is actually going on. I don't know if photos will explain very much, but I will try to explain how it is setup and wired.

Here is what I have:
X-Carve with upgraded rails, and gantry (aluminum rails with linear bearings)
2.2kw water cooled spindle 220v

I am on household 220v

My spindle is wired with #18 awg, braided sheilded wire. Pins 1,2,3 are wired to U,V,W on the VFD. The shielding is grounded at the VFD. Pin 4 I tried both running to the ground on the VFD and I tried it not wired to anything. (same results on both)
My VFD is wired directly to a dedicated 220v breaker (Black, Black, Green - Hot, Hot, Ground)

I'm not sure what other info is needed. I don't want anything to be unsafe and can't imagine what could possibly wrong.

Attachment 465286

So you have mounted the VFD on the wall with is own 240v Single Phase Power Supply and you have another 120v supply for the rest of your machines requirement's

By doing this you have a formed Ground loop and this is where some of your problems are coming from

I need close up photos of the VFD Drive wiring and the control box wiring to see how we can correct this

[mactec54]

18 awg. would be a little light for a 2.2Kw spindle