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IndustryArena Forum > CNC Electronics > Spindles / VFD > have Novusun with PWM and Sunfar E550 connection and setup problem
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  1. #1
    Join Date
    May 2012
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    1

    have Novusun with PWM and Sunfar E550 connection and setup problem

    Does anyone know how to connect and setup the Novusun PWM to a Sunfar E550. I've tried to make sense of the manuals, but they may as well be in Swahili. The spindle is a 24000rpm 400Hz 220volt unit. This works with the Start Stop button but I cannot seem to get switching from Mach3.

  2. #2
    Join Date
    May 2016
    Posts
    7

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    https://youtu.be/KUGo1UDT42sMake sure you have the setting right on the E500. My E500 VFD is driving a 220V 24000 RPM 400 Hz Spindle. The spindle is powered by a ST-3000 120 volt to 220 volt step up transformer. I am controlling spindle speed using MACH4. I am using MACH4's PWM output signal into a Leadshine MX4660 to produce my 0-10 Volts to E500 VFD . In my case MACH4 runs a ESS controller which controls a MX4660 4-Axis Stepper Drive with Breakout Board & I/O's. I believe though your setting would be similar depending on how you are controlling the motor forward and reverse options from you controller.

    E500 Settings:


    F0.00-1 > Set to external analog ... in my case produced by MX4660 from the PWM in MACH4
    F0.02-1001 >1-Is for external control, 0-Is for two line control mode 1 from (X1,X2 input pins), 0- Rev prevention, 1-Power on auto start
    F0.04-400 > My motor is 400 Hz
    F0.05-10 > I set Acceleration to 10 ... just a guess on my part
    F0.06-10 > I set Deceleration to 10 ... just a guess on my part
    F0.12-400 > My Motor Hz is 400
    F0.13-220 > My Motor Voltage is 220V
    F1.04-400 > My Motor Hz is 400 Hz

    F1.08-11 > Set at 11 so X1 input pin of E500 VFD is set up for foward motor operation. The X1 pin is tied to my MX4660 Output +5 and CM pin of E500 is tied to MX4660 Output -5 ... Note in my case the MX4660 output pin is open collector and emitter and rated for 100mA @ 24 volts so I did not require a relay.

    F1.09-12 > Set at 12 so X2 input pin of E500 VFD is setup for reverse motor operation. The X2 pin is tied to my MX4660 Output+6 and the CM pin of E500 is tied to Output -6. Note: again no relay required.

    I will attach video on how to actually program the E500 .... manual is not to clear.

    It took me a few days to finally get there manual understood but these setting got me going.

    Hope this helps

    Scott

  3. #3
    Join Date
    Mar 2013
    Posts
    14

    Talking Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Quote Originally Posted by Scotter View Post
    https://youtu.be/KUGo1UDT42sMake sure you have the setting right on the E500. My E500 VFD is driving a 220V 24000 RPM 400 Hz Spindle. The spindle is powered by a ST-3000 120 volt to 220 volt step up transformer. I am controlling spindle speed using MACH4. I am using MACH4's PWM output signal into a Leadshine MX4660 to produce my 0-10 Volts to E500 VFD . In my case MACH4 runs a ESS controller which controls a MX4660 4-Axis Stepper Drive with Breakout Board & I/O's. I believe though your setting would be similar depending on how you are controlling the motor forward and reverse options from you controller.

    E500 Settings:


    F0.00-1 > Set to external analog ... in my case produced by MX4660 from the PWM in MACH4
    F0.02-1001 >1-Is for external control, 0-Is for two line control mode 1 from (X1,X2 input pins), 0- Rev prevention, 1-Power on auto start
    F0.04-400 > My motor is 400 Hz
    F0.05-10 > I set Acceleration to 10 ... just a guess on my part
    F0.06-10 > I set Deceleration to 10 ... just a guess on my part
    F0.12-400 > My Motor Hz is 400
    F0.13-220 > My Motor Voltage is 220V
    F1.04-400 > My Motor Hz is 400 Hz

    F1.08-11 > Set at 11 so X1 input pin of E500 VFD is set up for foward motor operation. The X1 pin is tied to my MX4660 Output +5 and CM pin of E500 is tied to MX4660 Output -5 ... Note in my case the MX4660 output pin is open collector and emitter and rated for 100mA @ 24 volts so I did not require a relay.

    F1.09-12 > Set at 12 so X2 input pin of E500 VFD is setup for reverse motor operation. The X2 pin is tied to my MX4660 Output+6 and the CM pin of E500 is tied to Output -6. Note: again no relay required.

    I will attach video on how to actually program the E500 .... manual is not to clear.

    It took me a few days to finally get there manual understood but these setting got me going.

    Hope this helps

    Scott


    These setting work 100% I have been fooling with the manual for so long. I have the SUNFAR E550 with an air cooled 3.5 kw 220v spindle with running frequency of 300hz.


    Thank you for sharing your stup it helped me save hours and hous of time.

  4. #4
    Join Date
    Jan 2005
    Posts
    15362

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Quote Originally Posted by Scotter View Post
    https://youtu.be/KUGo1UDT42sMake sure you have the setting right on the E500. My E500 VFD is driving a 220V 24000 RPM 400 Hz Spindle. The spindle is powered by a ST-3000 120 volt to 220 volt step up transformer. I am controlling spindle speed using MACH4. I am using MACH4's PWM output signal into a Leadshine MX4660 to produce my 0-10 Volts to E500 VFD . In my case MACH4 runs a ESS controller which controls a MX4660 4-Axis Stepper Drive with Breakout Board & I/O's. I believe though your setting would be similar depending on how you are controlling the motor forward and reverse options from you controller

    F0.00-1 > Set to external analog ... in my case produced by MX4660 from the PWM in MACH4
    F0.02-1001 >1-Is for external control, 0-Is for two line control mode 1 from (X1,X2 input pins), 0- Rev prevention, 1-Power on auto start
    F0.04-400 > My motor is 400 Hz
    F0.05-10 > I set Acceleration to 10 ... just a guess on my part
    F0.06-10 > I set Deceleration to 10 ... just a guess on my part
    F0.12-400 > My Motor Hz is 400
    F0.13-220 > My Motor Voltage is 220V
    F1.04-400 > My Motor Hz is 400 Hz

    F1.08-11 > Set at 11 so X1 input pin of E500 VFD is set up for foward motor operation. The X1 pin is tied to my MX4660 Output +5 and CM pin of E500 is tied to MX4660 Output -5 ... Note in my case the MX4660 output pin is open collector and emitter and rated for 100mA @ 24 volts so I did not require a relay.

    F1.09-12 > Set at 12 so X2 input pin of E500 VFD is setup for reverse motor operation. The X2 pin is tied to my MX4660 Output+6 and the CM pin of E500 is tied to Output -6. Note: again no relay required.

    I will attach video on how to actually program the E500 .... manual is not to clear.

    It took me a few days to finally get there manual understood but these setting got me going.

    Hope this helps

    Scott
    A few other important Parameters you missed, you don't want to have a reverse connection, if you make a mistake in programing when the spindle is running at high speed you will fry the motor, and depending on the VFD these can be damaged as well, so it is a good idea to remove the wiring for Reversing

    When using Mach3 you usually need a relay to switch the on/off on the VFD , first get your PWM working out of Mach3 you can check the out put with a meter, before connecting it to the VFD

    F0.03=100 this is important minimum speed

    F0.07=1 this is for s-curve acceleration and Deceleration , this is not need but worth a try

    F2.19=1 this is your motor Pole setting 1= one pair of poles your motor is 2 pole so this needs to be set to ( 1 )
    Mactec54

  5. #5
    Join Date
    Mar 2013
    Posts
    14

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Yes I will not be using the reverse and will omit the wire. I am using the spindle for woodwork and will not be running reverse.


    I just ordered a c41 pwm board from cnc4pc.com and will use that board relay to short the cm and x1 pins on the vfd to turn it on. As for speed control I will have to figure that one out once I get the board.


    I did set the parameters just like you said. And spindle does sound very smooth and stays cool without load.

    Thanks again for your very helpful info




    Sent from my SM-N910V using Tapatalk

  6. #6
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    Jan 2005
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    15362

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Scotter

    Another important Parameter is this F3.13=100% this is to set the max currant the VFD can put out, but you need to calculate this as this is related to the VFD max out put Amps so if the VFD is 15 Amps and your spindle is 7 Amps then you will have to adjust this number to suit
    Mactec54

  7. #7
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    Mar 2013
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    14

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    My vfd is 24 amps at 220v and the spindle is 12 amps, so a setting of 50% on F3.13 would be ideal correct?

    Sent from my SM-N910V using Tapatalk

  8. #8
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    Jan 2005
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    15362

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Quote Originally Posted by sdcnc View Post
    My vfd is 24 amps at 220v and the spindle is 12 amps, so a setting of 50% on F3.13 would be ideal correct?

    Sent from my SM-N910V using Tapatalk
    Yes that would be ideal but as we just found out it only goes down to 150% will have to do some more checking into the use of this current control
    Mactec54

  9. #9
    Join Date
    May 2016
    Posts
    7

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Thanks Mac,

    For the tip ... I will for sure adjust my E550 max power setting setting!

    Scott

  10. #10
    Join Date
    May 2016
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    7

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Thanks Mac ... i will adjust my settings per your suggestions.

    FYI ... In my case my MX4660 has open collectors and emitters on the outputs and the VFD inputs are pulled up to about 24 volts so I did not require a relay.

  11. #11
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    Jan 2005
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    15362

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Quote Originally Posted by Scotter View Post
    Thanks Mac ... i will adjust my settings per your suggestions.

    FYI ... In my case my MX4660 has open collectors and emitters on the outputs and the VFD inputs are pulled up to about 24 volts so I did not require a relay.
    They show a switch or relay in there wiring diagrams
    Attached Thumbnails Attached Thumbnails Wiring Relay Use.PNG  
    Mactec54

  12. #12
    Join Date
    May 2016
    Posts
    7

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Mactec54 ... Yes they do and a transistor works really well as a switch! In the manual they list the CM pin as ground reference for the 24 volt power source on the E500. Whats important is to make sure to produce no ground loops and if possible isolation between the two. So if they can be done with what ever you are controlling the VFD it it would be nice. A relay reacquires an added power source and space to put it. Relays also have a couple other disadvantage they produce noise and they can also fail sense they are a mechanical device (I suppose you could also use solid state relay and get around this). In my case as I listed on the site I used the MX4660 isolated outputs to control the VFD without the need for a multi pole relay. The people at Leadshine really did a nice job in designing there outputs with basically and open transistor on there optocouplers so you can connect them and reference them to and higher voltages and external and independent grounds. In this case the E500 has 24 volts pulled up on each of there input terminals and the MX4660 output speck is noted not to exceed 70mA @ 24 volts. The MX4600 has internal built in current limiting resistors of 1k ohms on there optocouplers, so that means at 24 volts we only need to source 24mA of current, this is well within the 70mA speck of the MX4600 output pin. So again I am not telling anyone how to connect there gear but if you understand the system and there limitations you can do things another way. In the end in my case with what I had for gear I got full isolation no ground loops and no need for relays.

    I attach a video of my whole system if can help someone in doing there system all the better. My video skills are really lacking but maybe it can help others trying to similar controls.



    Regards Scott

  13. #13
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    Jan 2005
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    15362

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Scotter
    Don't worry about your video, I'm sure someone will get something out of it, what may help is if you do a drawing of what you connected your wires to from your PWM 0-10V to the Stop/Start control plus Parameter settings for this

    There are quite a lot of Leadshine users so could benefit from how you have connected to your MX4600

    What you have done is what most do to connect there VFD drives, for remote control use, this is basically the same setup for all VFD Drives, if a relay is used no additional power supply is needed well not normally anyway, the 12v or 24v from the VFD is used similar to how you are using it, and the output from your Breakout Board is for the other side of the Relay, and only solid state relays, anything else is history

    Most good quality Breakout Boards already have PWM and the Relays needed, built into the Boards for VFD Control
    Mactec54

  14. #14
    Join Date
    Aug 2017
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    5

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    mactec54,

    thank you for the good info everyone. I still have a question though. My setup is a Sunfar E550 connected to a 220v water cooled 240000 rpm 400hz 4.5kw spindle,GDZ-100-4.5. When I set the max rpm I only get 12000 rpm indicated on the VFD. I get this same rpm wether I use the VFD control or PWM. Can you Give me some guidance please.
    My settings are the same as Scotts.

  15. #15
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    15362

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Quote Originally Posted by dert428 View Post
    mactec54,

    thank you for the good info everyone. I still have a question though. My setup is a Sunfar E550 connected to a 220v water cooled 240000 rpm 400hz 4.5kw spindle,GDZ-100-4.5. When I set the max rpm I only get 12000 rpm indicated on the VFD. I get this same rpm wether I use the VFD control or PWM. Can you Give me some guidance please.
    My settings are the same as Scotts.
    You have to change Parameters to use the Keypad, There is also a Jumper that needs to be correct for 0-10v use check that it is in the ( V ) postion

    F0.00=3 For Pot control ( 1 ) For External Control 0-10v

    F0.02=1000 For KeyPad Control ( 1 ) For External Control ( 1001 )

    F0.03-120 ( 100 Minimum )

    F0.12=400

    F0.13=220

    F1.03=120 ( 100 Minimum )

    F1.04=400

    F2.19=1
    Mactec54

  16. #16
    Join Date
    Aug 2017
    Posts
    5

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Got it. All settings are the same. Except for the poles. I changed it to one and now the rpms indicate 24000. Looks like t was already spinning 24000 but just indicating 12000. Thanks for the info.


    Sent from my iPhone using Tapatalk

  17. #17
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    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Quote Originally Posted by dert428 View Post
    Got it. All settings are the same. Except for the poles. I changed it to one and now the rpms indicate 24000. Looks like t was already spinning 24000 but just indicating 12000. Thanks for the info.


    Sent from my iPhone using Tapatalk
    Yes the F2.19=1 motor Pole pairs is the part that most don't get, plus the Minimum RPM F0.3 and F1.03
    Mactec54

  18. #18
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    Aug 2017
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    5

    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    The spindle rotates very slowly, about 30 rpms, when the vfd is switched on but spindle is not set to spin in mach4. What can cause this?


    Sent from my iPhone using Tapatalk

  19. #19
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    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Quote Originally Posted by dert428 View Post
    The spindle rotates very slowly, about 30 rpms, when the vfd is switched on but spindle is not set to spin in mach4. What can cause this?


    Sent from my iPhone using Tapatalk
    This will damage the spindle so disconnect the logic wiring to the VFD Drive until you solve the problem

    Something is wired incorrect are you using a Relay to turn the VFD Drive On /Off
    Mactec54

  20. #20
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    Aug 2017
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    Re: have Novusun with PWM and Sunfar E550 connection and setup problem

    Quote Originally Posted by mactec54 View Post
    This will damage the spindle so disconnect the logic wiring to the VFD Drive until you solve the problem

    Something is wired incorrect are you using a Relay to turn the VFD Drive On /Off


    Here are some photos of my set up.
    Thank you for the info. I definitely don’t want to damage anything.
    I have the PWM analog signal coming out of the breakout board(Aout, port 1 pin 1) and into the vfd terminal AI(voltage signal input).
    The voltage out of the vfd(+10volts) on terminal VS(vfd) goes to breakout board terminal +Vin(not sure how to map this port/pin in Warp9 mach4 yet).
    Does this sound correct. I appreciate the help.



    Sent from my iPhone using Tapatalk

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