584,860 active members*
4,947 visitors online*
Register for free
Login
IndustryArena Forum > CNC Electronics > Spindles / VFD > HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!
Results 1 to 19 of 19
  1. #1
    Join Date
    Feb 2009
    Posts
    82

    HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Hello,

    When powering up and running the spindle for about 30s, its runs so very hot that you cant keep you hand over the spindle for a couple seconds! The spindle is rated for 8A and the VFD is rate at 10A. There is something I dont have correct as it seems the spindle is being electrically overloaded!

    I have gone through 2 VFDs now thinking that my VFD was defective but I get the same result so its definitely something I am doing wrong!



    VFD Info

    I have attached the VFD manual but it can also be seen online.

    Nowforever ES100S2R2 VFD link to manual: https://www.shopmasterusa.com/wp-con...NUAL-E-100.pdf



    VFD Settings:

    P0-000 = 0 [Select command source - set to keyboard control]

    P0-001 = 0 [Select frequency source - set to main frequency]

    P0-002 = 0 [Main frequency source - set to keyboard potentiometer]

    P0-003 = 0 [Assistant frequency source - set to keyboard potentiometer]

    P0-004 = 400 [Keyboard digital setting frequency]

    P0-005 = 5 [Jog frequency]

    P0-006 = 1 [Running direction - set to 1 to run the spindle clockwise]

    P0-007 = 400 [Upper frequency]

    P0-008 = 0 [Lower frequency]

    P0-009 = 8 [Accelerate speed time]

    P0-010 = 8 [Decelerate speed time]

    P0-011 = 6 [Carrier frequency]

    P0-012 = 1 [V/F curve setting - set to 50Hz motor, general load]

    P0-013 = 3 [Torque boost]

    P0-014 = 100 [Automatic torque compensation gain]

    P0-015 = 100 [Automatic slip compensation gain]

    P0-031 = 0 [Stop mode]

    P0-035 = 80 [Protection current of motor overload - set to 80% of VFD rated amps as motor is rated for 8A]

    P0-036 = 150 [Over-current protection value when losing steps]

    P0-037 = 130 [Over-voltage protection value when losing speed]



    Spindle Info

    Spindle being used is a GDZ-80F-2.2KW Air-Cooled Spindle



    Wiring Info

    Spindle: [Pin1 -> U], [Pin2 -> V], [Pin3 -> W], [Pin4 -> E]

    240VAC Power: [Black -> R], [White -> S], [Green -> E]

    Any help or feedback provided is much appreciated!
    Sam.

  2. #2
    Join Date
    Jan 2005
    Posts
    15362

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by shaffin View Post
    Hello,

    When powering up and running the spindle for about 30s, its runs so very hot that you cant keep you hand over the spindle for a couple seconds! The spindle is rated for 8A and the VFD is rate at 10A. There is something I dont have correct as it seems the spindle is being electrically overloaded!

    I have gone through 2 VFDs now thinking that my VFD was defective but I get the same result so its definitely something I am doing wrong!



    VFD Info

    I have attached the VFD manual but it can also be seen online.

    Nowforever ES100S2R2 VFD link to manual: https://www.shopmasterusa.com/wp-con...NUAL-E-100.pdf



    VFD Settings:

    P0-000 = 0 [Select command source - set to keyboard control]

    P0-001 = 0 [Select frequency source - set to main frequency]

    P0-002 = 0 [Main frequency source - set to keyboard potentiometer]

    P0-003 = 0 [Assistant frequency source - set to keyboard potentiometer]

    P0-004 = 400 [Keyboard digital setting frequency]

    P0-005 = 5 [Jog frequency]

    P0-006 = 1 [Running direction - set to 1 to run the spindle clockwise]

    P0-007 = 400 [Upper frequency]

    P0-008 = 0 [Lower frequency]

    P0-009 = 8 [Accelerate speed time]

    P0-010 = 8 [Decelerate speed time]

    P0-011 = 6 [Carrier frequency]

    P0-012 = 1 [V/F curve setting - set to 50Hz motor, general load]

    P0-013 = 3 [Torque boost]

    P0-014 = 100 [Automatic torque compensation gain]

    P0-015 = 100 [Automatic slip compensation gain]

    P0-031 = 0 [Stop mode]

    P0-035 = 80 [Protection current of motor overload - set to 80% of VFD rated amps as motor is rated for 8A]

    P0-036 = 150 [Over-current protection value when losing steps]

    P0-037 = 130 [Over-voltage protection value when losing speed]



    Spindle Info

    Spindle being used is a GDZ-80F-2.2KW Air-Cooled Spindle



    Wiring Info

    Spindle: [Pin1 -> U], [Pin2 -> V], [Pin3 -> W], [Pin4 -> E]

    240VAC Power: [Black -> R], [White -> S], [Green -> E]

    Any help or feedback provided is much appreciated!
    Sam.
    You may have to do Reset and then just reset these Parameters in this list which is almost the same as what you have, with a few extra ones

    Have you checked the continuity between the Pin 4 and the spindle body, this is not what is causing your over heating problem but must be checked, and corrected it is open, are you using shielded cable between the VFD and the spindle

    Now Forever VFD Drive Parameters
    Mactec54
    P0-000=1 ( 1 For Analog Control 0 For Key Board Control )

    P0-001=0

    P0-002=1

    P0-04=400

    P0-006=2

    P0-007=400

    P0-008=100

    P0-009=8 (Adjustable )

    P0-010=8 (adjustable )

    P0=011=8

    P0-012=1

    P0-024=400

    P0-030=1

    P0-036=100%

    P0-037=100%

    d1-003=?? ( VFD Rated Power )

    d1-004=?? ( VFD Rated Voltage )

    d1-005=?? ( VFD Rated Amps )

    d2-001=400

    d2-002=400

    d2-003=?? ( VFD Output Amps )

    d2-004=220

    d2-005=339 ( This is calculated using 240v if your voltage is higher than this I will have to give you a different number do you know your supply Voltage= ??

    You may not be able to set any of the d1 and d2 Parameters some are read only and auto ranging
    Mactec54

  3. #3
    Join Date
    Jan 2005
    Posts
    15362

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by shaffin View Post
    Hello,

    When powering up and running the spindle for about 30s, its runs so very hot that you cant keep you hand over the spindle for a couple seconds! The spindle is rated for 8A and the VFD is rate at 10A. There is something I dont have correct as it seems the spindle is being electrically overloaded!

    I have gone through 2 VFDs now thinking that my VFD was defective but I get the same result so its definitely something I am doing wrong


    Any help or feedback provided is much appreciated!
    Sam.
    I did not ask how slow have you been running it you most likely have a minimum speed of 12,000 RPM

    Is your spindle 24,000 RPM or 18,000RPM there is a big difference for the main Parameters so what are your spindle Spec's

    Voltage=220
    Amps=
    Hz=
    RPM=
    Mactec54

  4. #4
    Join Date
    May 2013
    Posts
    480

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    i find nowhere in that manual an option for setting the output minimum and maximum voltage.

    you have 6 options for the volts/hz curve, 50, or 60hz. P0-012=1




    as such what i think you will find with that VFD is that it will output the maximum voltage for any frequency above 50 or 60hz. this is why the motor is burning up at low speeds. you can verify this with 2 120vac lightbulbs in series across any two outputs of the vfd. (unless you have a 220vac lightbulb handy?) verify that they light up only dimply at 50hz. full brightness at 400hz.


    depending on how efficient your spindle motor is, you may burn it up at anything less than about 3/4th's the rated speed because the vfd is delivering 220vac regardless what the output frequency is if its above 50 or 60 hz. but technically you could try and use the spindle with that inverter if you only use it at full speed or a sufficient fraction of full speed to avoid over current problems.

  5. #5
    Join Date
    Feb 2009
    Posts
    82

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    The spindle spec is as follows:

    Voltage=220
    Amps=8
    Hz=400
    RPM=24000

  6. #6
    Join Date
    Feb 2009
    Posts
    82

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    I did set the parameters as you suggested, and after about 90s of running almost burnt my hand when placed over the spindle :-(

    These are the readings I found:

    d1-003=2.2 ( VFD Rated Power )

    d1-004=220 ( VFD Rated Voltage )

    d1-005=10 ( VFD Rated Amps )

    d2-001=400

    d2-002=62.20... (this reading was rising but i had to shut it down because the spindle was too hot)

    d2-003=10.6 ( VFD Output Amps )

    d2-004=35.1... (this reading was rising but i had to shut it down because the spindle was too hot)

    d2-005=328

  7. #7
    Join Date
    Feb 2009
    Posts
    82

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by Eldon_Joh View Post
    i find nowhere in that manual an option for setting the output minimum and maximum voltage.

    you have 6 options for the volts/hz curve, 50, or 60hz. P0-012=1




    as such what i think you will find with that VFD is that it will output the maximum voltage for any frequency above 50 or 60hz. this is why the motor is burning up at low speeds. you can verify this with 2 120vac lightbulbs in series across any two outputs of the vfd. (unless you have a 220vac lightbulb handy?) verify that they light up only dimply at 50hz. full brightness at 400hz.


    depending on how efficient your spindle motor is, you may burn it up at anything less than about 3/4th's the rated speed because the vfd is delivering 220vac regardless what the output frequency is if its above 50 or 60 hz. but technically you could try and use the spindle with that inverter if you only use it at full speed or a sufficient fraction of full speed to avoid over current problems.
    I dont have any 220v bulbs to test with :-(

  8. #8
    Join Date
    Jan 2005
    Posts
    15362

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by shaffin View Post
    The spindle spec is as follows:

    Voltage=220
    Amps=8
    Hz=400
    RPM=24000
    The only change I would make to the Parameter list I posted is P0.008=200

    This is only a safety as to how slow your spindle can run without cooking it's self

    Have you checked the Grounding and wiring
    Mactec54

  9. #9
    Join Date
    Feb 2009
    Posts
    82

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by mactec54 View Post
    The only change I would make to the Parameter list I posted is P0.008=200

    This is only a safety as to how slow your spindle can run without cooking it's self

    Have you checked the Grounding and wiring
    When I do a continuity test between Pin4 (on the spindle) and the spindle body - I get nothing.....

  10. #10
    Join Date
    Jan 2005
    Posts
    15362

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by shaffin View Post
    I did set the parameters as you suggested, and after about 90s of running almost burnt my hand when placed over the spindle :-(

    These are the readings I found:

    d1-003=2.2 ( VFD Rated Power )

    d1-004=220 ( VFD Rated Voltage )

    d1-005=10 ( VFD Rated Amps )

    d2-001=400

    d2-002=62.20... (this reading was rising but i had to shut it down because the spindle was too hot)

    d2-003=10.6 ( VFD Output Amps )

    d2-004=35.1... (this reading was rising but i had to shut it down because the spindle was too hot)

    d2-005=328
    The Buss voltage looks ok d2-005=328

    You have the parameters set correct, so I would say you have a problem with the spindle
    Mactec54

  11. #11
    Join Date
    Jan 2005
    Posts
    15362

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by shaffin View Post
    When I do a continuity test between Pin4 (on the spindle) and the spindle body - I get nothing.....
    As I though you have no Ground connection to the spindle body this is important, most with these air-cooled spindles remove the plastic cap and cut a notch out of the cap where one of the screws go through the cap, just enough to make clearance for a Ground terminal to be attached at this point and then back up to the plug where you can solder the connection
    Mactec54

  12. #12
    Join Date
    Jan 2005
    Posts
    15362

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by shaffin View Post
    I dont have any 220v bulbs to test with :-(
    And you don't need one
    Mactec54

  13. #13
    Join Date
    Jan 2005
    Posts
    15362

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by Eldon_Joh View Post
    i find nowhere in that manual an option for setting the output minimum and maximum voltage.

    you have 6 options for the volts/hz curve, 50, or 60hz. P0-012=1




    as such what i think you will find with that VFD is that it will output the maximum voltage for any frequency above 50 or 60hz. this is why the motor is burning up at low speeds. you can verify this with 2 120vac lightbulbs in series across any two outputs of the vfd. (unless you have a 220vac lightbulb handy?) verify that they light up only dimply at 50hz. full brightness at 400hz.


    depending on how efficient your spindle motor is, you may burn it up at anything less than about 3/4th's the rated speed because the vfd is delivering 220vac regardless what the output frequency is if its above 50 or 60 hz. but technically you could try and use the spindle with that inverter if you only use it at full speed or a sufficient fraction of full speed to avoid over current problems.
    Many have used this same VFD Drive, they have auto ranging for most of the Parameters as long as the main Parameters are set the VFD Drive is fine
    Mactec54

  14. #14
    Join Date
    Feb 2009
    Posts
    82

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by mactec54 View Post
    As I though you have no Ground connection to the spindle body this is important, most with these air-cooled spindles remove the plastic cap and cut a notch out of the cap where one of the screws go through the cap, just enough to make clearance for a Ground terminal to be attached at this point and then back up to the plug where you can solder the connection
    So if I understand correctly, if I open up the plastic cap and trace through the inside of Pin4 and run a ground wire to the body of the spindle that should work?

  15. #15
    Join Date
    Feb 2009
    Posts
    82

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    This is inside the cap!

    Click image for larger version. 

Name:	IMG_20190208_092721.jpg 
Views:	0 
Size:	287.2 KB 
ID:	411868

    Click image for larger version. 

Name:	IMG_20190208_092420.jpg 
Views:	0 
Size:	342.6 KB 
ID:	411870

  16. #16
    Join Date
    Feb 2009
    Posts
    82

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Just an update, tried to temporarily ground Pin4 to body but motor still burning up :-(

    Click image for larger version. 

Name:	IMG_20190208_115632.jpg 
Views:	0 
Size:	303.7 KB 
ID:	411882

  17. #17
    Join Date
    Jan 2005
    Posts
    15362

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by shaffin View Post
    Just an update, tried to temporarily ground Pin4 to body but motor still burning up :-(

    Click image for larger version. 

Name:	IMG_20190208_115632.jpg 
Views:	0 
Size:	303.7 KB 
ID:	411882
    The Ground won't stop the over heating, you would have to have the cap on for the air to cool the spindle though, check the air ways are clear while you have the cap off
    Mactec54

  18. #18
    Join Date
    Jan 2005
    Posts
    15362

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by shaffin View Post
    The spindle spec is as follows:

    Voltage=220
    Amps=8
    Hz=400
    RPM=24000
    Another thought is that the spindle may be etched 220v with the wrong voltage on it could be a 110v rated spindle

    Can you check the windings with a meter in ohms setting

    Pin1 to Pin 2=

    Pin2 to Pin3=

    Pin3 to Pin 1=
    Mactec54

  19. #19
    Join Date
    Jan 2005
    Posts
    15362

    Re: HELP ES100 VFD and 2.2KW spindle - SPINDLE RUNNING HOT/VFD ERROR!!!

    Quote Originally Posted by mactec54 View Post
    The Ground won't stop the over heating, you would have to have the cap on for the air to cool the spindle though, check the air ways are clear while you have the cap off
    Change this Parameter also as you are in NA

    P0-012=4
    Mactec54

Similar Threads

  1. Replies: 4
    Last Post: 06-12-2018, 10:59 AM
  2. torq cut spindle, need to run cnc with out spindle running
    By dholby in forum Bridgeport / Hardinge Mills
    Replies: 2
    Last Post: 10-04-2016, 08:53 PM
  3. Replies: 0
    Last Post: 12-24-2013, 04:28 PM
  4. mach3 spindle dro not working, spindle speed changing while jogging and running code
    By jasminder in forum Mach Software (ArtSoft software)
    Replies: 0
    Last Post: 02-23-2011, 07:12 AM
  5. Spindle not Running
    By Simon Lee in forum DIY CNC Router Table Machines
    Replies: 1
    Last Post: 02-09-2007, 06:56 PM

Tags for this Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •