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
Mactec54
My water spindle is wired similarly: 1,2,3,4 is U, W, V, then ground. Swapped W and V to reverse. Using a 220 line to an old heat pump with its own breaker. Also have the outside of the spindle grounded for extra precaution. Machine is plugged into a standard 110 outlet.
I never had a problem.
Many other differences like I’m using a relay circuit to start the spindle off Pokeys57cnc that is attached to a pc using an Ethernet cable running Mach4. CAM is vectric.
Seems like there are many signals and screens in Mach to debug this. Especially if it happens every time.
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Mactec54
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Yes... 240 v (measures at 239ish)
How can I troubleshoot the grounding loop? I can't figure out where it would be creating a loop? Currently, the control board is plugged into a 120v line and thus is grounded there. The machine rails and gantry are grounded to the 240v line ground, and the spindle is grounded to the the 240v ground.
The setups I have tried have had the rails etc. grounded to the control board... The rails etc. not grounded to anything... The spindle (before I separated it with the phenolic plate) grounded to the control board... spindle grounded to vfd. I think I tried every combo of grounding I could think of.
What am I missing? Are there any tricks to finding grounding loops?
You really have it quite messed up Grounding is simple just has to be done correctly
You are using ( 2 ) power source's a 120v supply and a 240v supply for ( 1 ) machine you have ( 2 ) separate Grounds ( 1 ) Ground for the 120v supply and ( 1 ) Ground for the 240v supply this is where your Ground loop comes from, a Ground loop is formed when you use ( 2 ) different supplies for the same machine
You should only have ( 1 ) power supply source for your machine
How do you fix this you use a 240v 4 wire supply this is the correct way to do it and the only way to avoid a Ground loop
So the 240v supply will have 2 Hot a Neutral and Ground, which will give you 240v / 120v supply for your machine you split it up from there to where it needs to go
You VFD Drive also needs to be mounted in a metal Box also or at the least on an aluminum / steel plate so this can be the Ground Plane
And a EMI Power Filter at the VFD Drive supply input will be needed, this is the Power Filter you need
TDK Lambda RSEN-2030L There are no substitutes these are the best EMI Power Filter for your install
None of these things will change until the VFD Drive is mounted correctly and the Power supply is corrected
So first figure out your 240v main power supply 4 wire should be a minimum of 25A supply 30A is better for your machine, and I will help you get the rest of your wiring done how it should be
Will need photos as you progress
Mactec54
Not many people understand, and there are plenty that will give you an uneducated guess, of what they think will work, which in most cases is incorrect
Can you imagine a Company selling a CNC machine or any type of machine and telling the customer that you will need a 240v service and a 120v service to run there machine this is not going to happen, in reality, NA is the only part of the world that uses 120v Single Phase all the rest use 220v / 230 / 240v for single Phase so most will never have to encounter this problem, the Best for anyone in NA that is Building a Machine is to use 240v for everything
You have a lot of little things that need to be corrected, so start with the 240v Power service, then we will move to the EMI Power Filter and the mounting of the VFD Drive either in a Box or on a metal plate this plate needs to be big enough for the Power filter and a breaker for the 120v supply and a place to mount a Ground Bus
A Box with a fan is best as this will help to keep the dust out of the VFD Drive, they don't last very long if they can suck in any dust, if a Box this can be plastic but must have a metal Plate inside that everything is mounted on
Mactec54
I make my own custom for each build, but any Metal enclosure that you can fit everything in, they are never big enough so don't get it to small, you can find some good deals on used and new boxes on eBay, they may have holes and cutout that you can fill, make sure it is deep enough as well so figure out some rough dimension's and see what is close to what you need so if you measure your VFD Drive how tall it is and add 2" that should be how deep you want the box to be Plastic enclosures are ok as well as long as they have a metal mounting plate inside
Mactec54
So this thread has gone on for almost a month. The original issues is the machine stops mid program. Then this ground loop theory came up, even though my machine is set up exactly the same and I apparently also have ground looping, but have never had an issue.
It would be great if after all these changes are made that we hear if the original problem is solved.
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Where is the best location for the TDK Lambda RSEN-2030L. Closer to main panel or Closer to VFD. Thanks
If this is just for the VFD Drive, you want it as close as you can to the input power supply to the VFD Drive, either to the side of the VFD Drive or directly in front, if using single phase supply Twist, the 2 power wires together but not the Ground, have a good Grounding Bus or Star Point Grounding stud where all your Ground wires are connected
Mactec54