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  1. #1
    Join Date
    Jul 2010
    Posts
    172

    Mini Mill VFD problem

    I have a 2001 Mini Mill that's has been giving me some problems for the last couple of months.
    It used to happen once in a while but now the machine won't make it through a single program.
    Error code 123.
    Fault happens during spindle start.
    Programmed RPM doesn't matter, happens at 500rpm and up to 6000rpm.
    Also happens during a tool change occasionally.
    All the voltages are correct at 240 single phase with a large ground wire installed.
    None of the drives are showing a red fault light.
    Fans are running on the drives and the power source.
    Ambient temperature is a comfortable 70deg F.
    More likely to happen after the machine has run for an hour or two vs. first thing in the morning.
    I measured the spindle motor winding at 0.001ohms between all three pairs.

    Any ideas?

    Timothy
    Dyna Mechtronics DM4400, Bridgeport Discovery 300, HAAS VF-0E, HAAS VF-2D
    BobCad 16, 20, 24 and now V25

  2. #2
    Join Date
    Jan 2005
    Posts
    15362

    Re: Mini Mill VFD problem

    Quote Originally Posted by 2ferrous View Post
    I have a 2001 Mini Mill that's has been giving me some problems for the last couple of months.
    It used to happen once in a while but now the machine won't make it through a single program.
    Error code 123.
    Fault happens during spindle start.
    Programmed RPM doesn't matter, happens at 500rpm and up to 6000rpm.
    Also happens during a tool change occasionally.
    All the voltages are correct at 240 single phase with a large ground wire installed.
    None of the drives are showing a red fault light.
    Fans are running on the drives and the power source.
    Ambient temperature is a comfortable 70deg F.
    More likely to happen after the machine has run for an hour or two vs. first thing in the morning.
    I measured the spindle motor winding at 0.001ohms between all three pairs.

    Any ideas?

    Timothy
    What are the power supply Amps you have
    Mactec54

  3. #3
    Join Date
    Jul 2010
    Posts
    172

    Re: Mini Mill VFD problem

    No idea.

    I've removed the drive and boxed it for shipping to a repair/test shop.

    Timothy
    Dyna Mechtronics DM4400, Bridgeport Discovery 300, HAAS VF-0E, HAAS VF-2D
    BobCad 16, 20, 24 and now V25

  4. #4
    Join Date
    Jan 2005
    Posts
    15362

    Re: Mini Mill VFD problem

    Quote Originally Posted by 2ferrous View Post
    No idea.

    I've removed the drive and boxed it for shipping to a repair/test shop.

    Timothy
    Put it a different way what is the Breaker Size that is supplying the Power to the machine was this wired to Haas spec's

    There may be nothing wrong with the drive

    Check the braking Resistor on top of the cabinet, and clean all the chips out of there
    Mactec54

  5. #5
    Join Date
    Jul 2010
    Posts
    172

    Re: Mini Mill VFD problem

    Funny you should ask that.
    Breaker supplying the Mini Mill is a 40 amp three pole breaker. One pole unused. 240vac supply voltage.
    Originally I had a 10/3 (6 strand) tek cable running the 20ft to the machine.
    All leads and lines inside the cabinet switched for the 240vac single phase.
    It draws 18 to 20 amps under load.
    Then in December last year I installed another machine beside it and wired/rewired both of them.
    Each with 8/3 (6 strand) BX cable and their own 40 amp breaker.
    That is when the problems started.

    Wondering if I should switch back to the tek cable.

    Timothy
    Dyna Mechtronics DM4400, Bridgeport Discovery 300, HAAS VF-0E, HAAS VF-2D
    BobCad 16, 20, 24 and now V25

  6. #6
    Join Date
    Jan 2005
    Posts
    15362

    Re: Mini Mill VFD problem

    Quote Originally Posted by 2ferrous View Post
    Funny you should ask that.
    Breaker supplying the Mini Mill is a 40 amp three pole breaker. One pole unused. 240vac supply voltage.
    Originally I had a 10/3 (6 strand) tek cable running the 20ft to the machine.
    All leads and lines inside the cabinet switched for the 240vac single phase.
    It draws 18 to 20 amps under load.
    Then in December last year I installed another machine beside it and wired/rewired both of them.
    Each with 8/3 (6 strand) BX cable and their own 40 amp breaker.
    That is when the problems started.

    Wondering if I should switch back to the tek cable.

    Timothy
    You don't have enough supply they require a 60A supply for Single Phase 6 Gauge wire Haas factory spec's

    The Mini Mill Spec's are 40A full load so your wiring and supply has to be greater than that, we don't have any problem with our machines which have 60A supply the electrical code also would require a 60A wiring
    Mactec54

  7. #7
    Join Date
    Jul 2010
    Posts
    172

    Re: Mini Mill VFD problem

    This is something other than electrical supply.
    I've been running this mill for over a year with no blown breakers or any other problems.
    The spindle fault is popping up within micro seconds of a M3.
    It's like it's not even trying to spin up.
    I have a feeling the caps are gone in the drive.

    Timothy
    Dyna Mechtronics DM4400, Bridgeport Discovery 300, HAAS VF-0E, HAAS VF-2D
    BobCad 16, 20, 24 and now V25

  8. #8
    Join Date
    Jan 2005
    Posts
    15362

    Re: Mini Mill VFD problem

    Quote Originally Posted by 2ferrous View Post
    This is something other than electrical supply.
    I've been running this mill for over a year with no blown breakers or any other problems.
    The spindle fault is popping up within micro seconds of a M3.
    It's like it's not even trying to spin up.
    I have a feeling the caps are gone in the drive.

    Timothy
    Yes the caps could be tired, they are the normal parts to fail first, but your electrical supply is also incorrect it has nothing to do with Breakers tripping, it's the spec's that Haas require, for single phase and the electrical code for wire size
    Mactec54

  9. #9
    Join Date
    Jul 2010
    Posts
    172

    Re: Mini Mill VFD problem

    Problem sorted out.

    As mactek54 suggested, I installed a new 60amp breaker with a 6ga cable to the mini mill.
    I unboxed the spindle drive as I hadn't shipped it out yet and wired it back in.
    The fault was even more pronounced than ever before.
    I couldn't even turn on the spindle without a tool in it.

    So out came the drive and off it went to a repair facility in Illinois.
    They easily replicated the fault and offered two solutions, repair the existing drive or replace with a NOS updated model.
    I opted for the NOS drive and sent the money.

    It arrived last week and now the Mini Mill is back up and running.
    Ran a full 8 hours yesterday without a hiccup.

    Timothy
    Dyna Mechtronics DM4400, Bridgeport Discovery 300, HAAS VF-0E, HAAS VF-2D
    BobCad 16, 20, 24 and now V25

  10. #10
    Join Date
    Jan 2005
    Posts
    15362

    Re: Mini Mill VFD problem

    Quote Originally Posted by 2ferrous View Post
    Problem sorted out.

    As mactek54 suggested, I installed a new 60amp breaker with a 6ga cable to the mini mill.
    I unboxed the spindle drive as I hadn't shipped it out yet and wired it back in.
    The fault was even more pronounced than ever before.
    I couldn't even turn on the spindle without a tool in it.

    So out came the drive and off it went to a repair facility in Illinois.
    They easily replicated the fault and offered two solutions, repair the existing drive or replace with a NOS updated model.
    I opted for the NOS drive and sent the money.

    It arrived last week and now the Mini Mill is back up and running.
    Ran a full 8 hours yesterday without a hiccup.

    Timothy
    Good to hear

    The main thing is you have the correct wiring now, which will help the new drive have a longer life, what did they replace it with, it would be interesting to Know so when others have a drive problem they have an option to replace them in stead of a Haas VFD drive
    Mactec54

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