[lowslo]

New machine. FLA 100. New Chinese spindle(Hyunyang 2.2kw). I'm getting an e stop almost as soon as the tool starts cutting. I've heard these cheap spindles and VFD's are noise factories too.

The error is "external e stop requested". I've disconnected the e stop switch and set the e stop to active low to try and isolate the issue. This made zero difference. Is the problem really noise on the e stop pin, or could it be noise from limit switch wiring as well? Would noise on a limit switch line not cause a false limit trigger?

I have made a moderate investment (for me) in this machine and in time putting it all together. Getting frustrated! Thank you in advance!

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[awerby]

Is there any shielding on the cable between the VFD and the spindle? That can be a major source of RFI. Most people say to use a braided metallic shield and ground it on one end only (usually the spindle end) although there are those who say you can ground both ends.

[Al_The_Man]

Do you have proper earth grounding on the machine and to the frame of the spindle?
Also the various parts of the machine frame bonded to earth?
Al.

[lowslo]

Is there any shielding on the cable between the VFD and the spindle? That can be a major source of RFI. Most people say to use a braided metallic shield and ground it on one end only (usually the spindle end) although there are those who say you can ground both ends.

No. The VFD cable is not shielded. I may order some shielded cable and replace it. I find it odd that I'm getting false e stops and the FVD cable is a long ways from the e stop wiring.

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[lowslo]

Do you have proper earth grounding on the machine and to the frame of the spindle?
Also the various parts of the machine frame bonded to earth?
Al.

The machine frame is grounded to mains ground. The spindle mount is aluminum and has continuity through the frame, but that does go through the linear motion bearings.

I'm also using the spindle mount for the probe wire attachment point, as this has continuity through the tool. I could remove this and see if that may be where the noise is being introduced.

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[lowslo]

The machine frame is grounded to mains ground. The spindle mount is aluminum and has continuity through the frame, but that does go through the linear motion bearings.

I'm also using the spindle mount for the probe wire attachment point, as this has continuity through the tool. I could remove this and see if that may be where the noise is being introduced.

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I ran a small part by zeroing the tool and then removing the probe connection from the spindle mount. E stop within a minute. Not to say this isn't how the noise is being introduced, but there was no physical connection of the probe wire to the machine.

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[awerby]

You don't need a physical connection; RFI can travel through the air. You also don't need to replace your existing cables, just slip a braided shield over the whole bundle that goes from the VFD to the spindle. Like this stuff: https://www.cableorganizer.com/metal-braided-sleeving/

[lowslo]

You don't need a physical connection; RFI can travel through the air. You also don't need to replace your existing cables, just slip a braided shield over the whole bundle that goes from the VFD to the spindle. Like this stuff: https://www.cableorganizer.com/metal-braided-sleeving/

Thanks for everyones input and assistance. It's wierd that it will cut air without issue, but as soon as the tool touches the workpiece it triggers an e stop.

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[Al_The_Man]

The machine frame is grounded to mains ground. The spindle mount is aluminum and has continuity through the frame, but that does go through the linear motion bearings.

You should Never rely on earth GND through linear bearings, a proper earth conductor is needed.
Not to mention the fact that the bearings can receive damage if a heavy GNF fault occurs
Al.

[ger21]

DIsable the limits and see if it still does it.

[lowslo]

DIsable the limits and see if it still does it.

How do you do it Gerry?

That was it. AGAIN, you have helped me.

A big thank you to all those that helped me narrow it down and make suggestions. I guess I need to rework my limit switch wiring and harden it against noise better. It's strange that noise on the limit switch wiring was being interpreted as an e stop request.

I plan on upgrading some other potential ground issues that have been pointed out and installing a secondary ground rod for the low voltage side.

Thank you all once again

Ryan

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