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  1. #13
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    Apr 2005
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    478

    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    The spindle and drive were purchased in June of 2017 off ebay and have been used for the last 2 years on this machine.

    2.2KW ER20 FOUR BEARING AIR-COOLED SPINDLE MOTOR & 2.2KW INVERTER DRIVE VFD TOP
    ( 171841127523 )

    It is no longer listed on the motormall store but I am sure it is the same as all the others out there.

    I don't know the exact data of the motor

    This is 220v single phase, two loads and a ground (going by memory) loads to RS and Ground to Earth

    UVW to spindle - ground to housing


    CHris D

  2. #14

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    9826

    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    Quote Originally Posted by Chris D View Post
    The spindle and drive were purchased in June of 2017 off ebay and have been used for the last 2 years on this machine.

    2.2KW ER20 FOUR BEARING AIR-COOLED SPINDLE MOTOR & 2.2KW INVERTER DRIVE VFD TOP
    ( 171841127523 )

    It is no longer listed on the motormall store but I am sure it is the same as all the others out there.

    I don't know the exact data of the motor

    This is 220v single phase, two loads and a ground (going by memory) loads to RS and Ground to Earth

    UVW to spindle - ground to housing


    CHris D

    That is correct if you know what Kw and the RPM then they all have much the same spec's

    R and S is Ok but R and T is more reliable for these HY VFD Drives

    What is the Cable that you have from the VFD Drive to the Spindle and how have you done the Ground Photo would be good
    Mactec54

  3. #15

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    Jan 2005
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    9826

    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    Apart from you spindle VFD wiring which would be good to see I think you where creating a short with you PWM output and your Pot you can't have both connected at the same time or not how you have it wired anyway

    So disconnect the pot and connect the VI and ACM only to your PWM out put 0-10v and connect the relay as you had it to FOR and DCM
    Mactec54

  4. #16
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    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    Hi Mactec54,

    The pot and the PWM/Analog were/are never connected to the VFD at the same time. They are mutually exclusive.

    Chris D

  5. #17

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    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    Quote Originally Posted by Chris D View Post
    Hi Mactec54,

    The pot and the PWM/Analog were/are never connected to the VFD at the same time. They are mutually exclusive.

    Chris D
    I'm thinking that the PWM board is what has the problem the VFD works fine when not connected to the Breakout Board so something has happened with that part, or there is something with the spindle wiring that is causing lots of noise

    What changed you said you ran it for 2 years, did you add the PWM control and this is when it failed
    Mactec54

  6. #18
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    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    I changed a lot during the last month. I did add the PWM control, however, it was working and I used the machine at that time to run some parts.

    "Noise " being the problem also seems unlikely. I can get the spindle running and controlled by the PWM signal, I can start and stop it (By twisting together the DCM & FOR) wires and not have any problems at all. I can also do the same with the pot instead of the PWM signal. In these cases, the noise should be present and have the same cause and effect I would think.

    With that said, I have a new relay board on order and a new and different PWM/Analog board on order to swap them out and see if there is a cause effect doing that. Beyond that, the next thing to replace would be the VFD, perhaps something is wacky in that thing?

    I also have an oscilloscope, I might try running some tests with the scope and maybe I will see a spike or drop in voltage somewhere that might be causing this problem.

    Chris D

  7. #19

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    9826

    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    Quote Originally Posted by Chris D View Post
    I changed a lot during the last month. I did add the PWM control, however, it was working and I used the machine at that time to run some parts.

    "Noise " being the problem also seems unlikely. I can get the spindle running and controlled by the PWM signal, I can start and stop it (By twisting together the DCM & FOR) wires and not have any problems at all. I can also do the same with the pot instead of the PWM signal. In these cases, the noise should be present and have the same cause and effect I would think.

    With that said, I have a new relay board on order and a new and different PWM/Analog board on order to swap them out and see if there is a cause effect doing that. Beyond that, the next thing to replace would be the VFD, perhaps something is wacky in that thing?

    I also have an oscilloscope, I might try running some tests with the scope and maybe I will see a spike or drop in voltage somewhere that might be causing this problem.

    Chris D
    If the VFD runs it is fine, and both of the connections are working FOR and DCM and VI and the Pot connections so the problem is you connection in between, remove the PWM Board and just use a relay by it's self, use an output to turn the Relay on /off and connect the output of the relay direct to FOR and DCM this will be a good test if this fails then there is noise with the relay switching that is causing your Breakout Board to fault and will need a snubber attached to the relay
    Mactec54

  8. #20
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    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    It is going to be a long week and a half before I get back to the shop for further testing. My focus is certainly on the Relay board and I was told by my wife the replacement arrived today.

    Thanks Mactec54

  9. #21
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    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    Well, after replacing my relay board and my digital to analog board and a bunch more testing, the problem is a "noise" related problem. The new relay board did nothing nor did the digital to analog board.

    What did help was changing the "debounce" setting for E-stop in the ESS configuration settings. That had an immediate effect and improvement. The noise is, from what I can determine, causing false signals to be interpreted by the I-Pac USB keyboard encoder.

    The I-Pac is in a separate enclosure (about 4 feed from the main enclosure) connected to the PC via a USB cable. I also have a cable running from the main enclosure to that enclosure with other I/O to power LEDs, and handle encoders and the MPG.

    If I disconnect that cable, everything runs fine with no false signals. When I connect that cable, I start getting random signals through the I-PAC. I suspect that the "noise" is coming through on that cable somehow.

    Determining the exact solution is a mystery to me other than just trial and error.

    Chris

  10. #22
    Community Moderator ger21's Avatar
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    33776

    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    Try some ferrite chokes on the USB cable.
    Gerry

    UCCNC 2017 Screenset
    http://www.thecncwoodworker.com/2017.html

    Mach3 2010 Screenset
    http://www.thecncwoodworker.com/2010.html

    JointCAM - CNC Dovetails & Box Joints
    http://www.g-forcecnc.com/jointcam.html

    (Note: The opinions expressed in this post are my own and are not necessarily those of CNCzone and its management)

  11. #23
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    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    Hi Gerry,
    Already on the cable.

    Chris

  12. #24

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    Re: Mach3 - ESS smooth stepper - Huanyang Chinese VFD - Mach 3 e-stopping???

    Quote Originally Posted by Chris D View Post
    Well, after replacing my relay board and my digital to analog board and a bunch more testing, the problem is a "noise" related problem. The new relay board did nothing nor did the digital to analog board.

    What did help was changing the "debounce" setting for E-stop in the ESS configuration settings. That had an immediate effect and improvement. The noise is, from what I can determine, causing false signals to be interpreted by the I-Pac USB keyboard encoder.

    The I-Pac is in a separate enclosure (about 4 feed from the main enclosure) connected to the PC via a USB cable. I also have a cable running from the main enclosure to that enclosure with other I/O to power LEDs, and handle encoders and the MPG.

    If I disconnect that cable, everything runs fine with no false signals. When I connect that cable, I start getting random signals through the I-PAC. I suspect that the "noise" is coming through on that cable somehow.

    Determining the exact solution is a mystery to me other than just trial and error.

    Chris
    What is powering what you have in the other cabinet or are both using the same Ground if not you will have a Ground loop which will cause you noise problems, is the USB cable double shielded

    Debounce is a help but only a temporary fix
    Mactec54

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