[justinwol]

Hello,

Just got my Chinese 2.2kw water cooled spindle and VFD connected and put it through some tests. Thanks to all the available information out there everything went smooth and seemed to work well.

However, after successfully testing the unit for a while (20 mins), I stopped it and checked pd177-180 for error codes and each one showed an error code as follows:

pd177: ELu.n
pd178: ELu.d
pd179: ELu.A
pd180: EEr.n

From the manual I understand these to mean a Low Voltage fault during accel/decel/constant run as well as an External Interference fault during constant run.

The VFD is connected to 240V and spindle is connected via shielded 18 AWG wire.

Does anyone know what common causes for these faults would be? Also is there a way to clear the fault codes? I have not discovered a method yet.

Thanks,
Justin

[justinwol]

After another look through the manual I found the fault clear parameter - pd172. Setting this to 1 will clear the faults.

[mactec54]

After another look through the manual I found the fault clear parameter - pd172. Setting this to 1 will clear the faults.

It is not advisable to do a Factory Reset unless you really have to quite often this can mess up these Huangang VFD Drives

So did the Faults stop the Spindle from running ???

Or was it just faults in the fault registry, these can be just from the factory when they tested the Drive or from someone that may have returned it

So what parameters do you have set, t is important that you have them correct for the health of your spindle and drive

[justinwol]

FWIW, I noticed that many of the parameters were already set to what I needed rather than the factory default. It is possible this unit was tested/used and not reset to factory. So I did a factory reset (should've been the first thing I did in hindsight, but didn't know what I was doing yet), cleared the fault codes, and have been testing error free for a while.

[handlewanker]

So, I'm assuming your water cooled spindle is a 1 HP 240 volt 3 phase model (7,000 rpm?) and runs from a 2.2Kw (3Hp) VFD...….not a water cooled 24,000rpm brushless type?
Ian.

[justinwol]

@handlewanker HY02D223B Huangyang VFD (2.2KW 11A) with a 2.2KW water cooled spindle (24,000rpm).

@mactec54 The faults did not seem to affect the operation at all - it seemed to run fine. Here are the parameters I set after resetting the VFD:

PD001 = 0
PD002 = 1
PD003 = 120
PD004 = 400
PD005 = 400
PD006 = 2.5
PD007 = 0.5
PD008 = 220
PD009 = 15
PD010 = 8
PD011 = 100
PD014 = 12
PD015 = 12
PD070 = 1
PD072 = 400
PD073 = 100
PD141 = 220
PD142 = 9
PD143 = 2
PD144 = 3000

Seems to be working fine, temperature is cool both to touch and the water. No faults have shown up yet.

Thanks for the help guys. This is way I posted here, to get some feedback/criticism before I begin operating it regularly.

[mactec54]

@handlewanker HY02D223B Huangyang VFD (2.2KW 11A) with a 2.2KW water cooled spindle (24,000rpm).

@mactec54 The faults did not seem to affect the operation at all - it seemed to run fine. Here are the parameters I set after resetting the VFD:

PD001 = 0
PD002 = 1
PD003 = 120
PD004 = 400
PD005 = 400
PD006 = 2.5
PD007 = 0.5
PD008 = 220
PD009 = 15
PD010 = 8
PD011 = 100
PD014 = 12
PD015 = 12
PD070 = 1
PD072 = 400
PD073 = 100
PD141 = 220
PD142 = 9
PD143 = 2
PD144 = 3000

Seems to be working fine, temperature is cool both to touch and the water. No faults have shown up yet.

Thanks for the help guys. This is way I posted here, to get some feedback/criticism before I begin operating it regularly.

So as I said they where nothing to worry about as what is in the fault report has nothing to do with how it is running, they probably where from the factory testing and where never cleared, you have to be careful what you mess with

PD003=400 not 120 ( Main Frequency )

PD007=20

PD014= is adjustable normally can get them down to around 3s to 6s without a fault

PD015= is adjustable the same as well

PD174= ??? ( To Be Set to the VFD Drives Max Rated Output Amps )

The temperature on the outside is not an indication of the temperature on the inside the water does a good job most of the time though, have the water run longer when the spindle turns off

Do you have the Ground wire 4th Pin in the spindle connected this is a must to check that it is Grounded to the body of the spindle

[justinwol]

@mactec54 Thanks!

PD174 = 11 (Factory default - VFD is rated at 11 amps)

PD003 sets Speed 1 when in digital operator mode (PD002 = 0) otherwise in external control mode (PD002 = 1) Speed 1 is set by the analog input, in my case the potentiometer on the VFD. Currently, this setting is irrelevant. I set 120 on the initial run, but then switched to analog mode.

PD007 Can you help understand this parameter, I've yet to quite nail it down.

PD014 & PD015 Good to know! I have yet to fine tune these.

Grounding the spindle (4th pin) was the first thing I did. My tests revealed it was not grounded...

Water cooling - good idea, I will definitely run the cooling system for some time after spindle turns off.

Again, really appreciate your input, thank you.

[mactec54]

@mactec54 Thanks!

PD174 = 11 (Factory default - VFD is rated at 11 amps)

PD003 sets Speed 1 when in digital operator mode (PD002 = 0) otherwise in external control mode (PD002 = 1) Speed 1 is set by the analog input, in my case the potentiometer on the VFD. Currently, this setting is irrelevant. I set 120 on the initial run, but then switched to analog mode.

PD007 Can you help understand this parameter, I've yet to quite nail it down.

PD014 & PD015 Good to know! I have yet to fine tune these.

Grounding the spindle (4th pin) was the first thing I did. My tests revealed it was not grounded...

Water cooling - good idea, I will definitely run the cooling system for some time after spindle turns off.

Again, really appreciate your input, thank you.

Not at all PD003=400 that's the main Frequency that the Pot or the Keypad requires for manual control you can not set this lower than your spindle max Frequency

PD007=20 is the starting Frequency 20Hz .05 is to low when you have to jump up to 400Hz or the minimum speed at 100Hz

The setting of main frequency is limited by the maximum operating frequency.

[justinwol]

PD007 - Thanks!

PD003 - My particular VFD works the way I described and is explicitly stated in the manual as such, you might be referring to a different VFD. I have verified that my particular VFD functions this way as well. Setting PD002 = 0 and setting PD003 = 100 the spindle will initially spin up to 6000rpm. If I change the frequency using the arrow keys say to 120hz the spindle spins up to 7200rpm. At this point, I can stop the spindle and go and check PD003 and it will now read 120 (as stated in the manual attached here). Changing PD002 = 1 changes the main frequency to the pot - PD003 is no longer used. As such I can leave PD003 at 120, but turn the pot up to 400hz and on run the spindle will spin up to 400hz (24,000rpm) not 120hz. Any changes done to the pot do not affect PD003 setting, in this case it will stay at 120.

You've been super helpful and I consider all my issues resolved. Thanks again!

[mactec54]

PD007 - Thanks!

PD003 - My particular VFD works the way I described and is explicitly stated in the manual as such, you might be referring to a different VFD. I have verified that my particular VFD functions this way as well. Setting PD002 = 0 and setting PD003 = 100 the spindle will initially spin up to 6000rpm. If I change the frequency using the arrow keys say to 120hz the spindle spins up to 7200rpm. At this point, I can stop the spindle and go and check PD003 and it will now read 120 (as stated in the manual attached here). Changing PD002 = 1 changes the main frequency to the pot - PD003 is no longer used. As such I can leave PD003 at 120, but turn the pot up to 400hz and on run the spindle will spin up to 400hz (24,000rpm) not 120hz. Any changes done to the pot do not affect PD003 setting, in this case it will stay at 120.

You've been super helpful and I consider all my issues resolved. Thanks again!

What you are saying is correct but if you use the Keypad only, it must be set at the max main Frequency of your spindle =400Hz to get the max spindle RPM using the Keypad using the remote control bypasses this part of the KeyPad as you are saying it is standard practice to set it to the max from the start

Same VFD Drive I have done hundreds of them and repaired them also

[justinwol]

if you use the Keypad only, it must be set at the max main Frequency of your spindle =400Hz to get the max spindle RPM using the Keypad

I'm not sure we have the same model (HY02D223B) or version (Vr1.000). This is not how mine works. P003 does not prevent max spindle RPM if below 400 (max Hz of spindle) when using the keypad. I'm done here now, but as a courtesy, see below if you're interested in the difference between my VFD and the ones you work on regarding PD003's operation.

Again, very much appreciate your help!


This is how PD003 parameter works on the HY02D223B that I have (some of this has already been stated, but for completeness I included it):

First, PD003 applies to the keypad mode only or as the manual says "digital operator mode". Setting PD002 = 1 changes to "external control multi-speed mode" and PD003 is not used.

Using the keypad mode only (PD002 = 0), PD003 must be set between PD005(max Hz) and PD011(min Hz) - in my case 400 and 100 respectively. It doesn't matter if PD003 is 100 or 400, you can still get the max spindle rpm (24,000) using the keypad.

For example, the settings PD002 = 0 (keypad only), PD005 = 400, PD011 = 100, PD003 = 100 will simply result in the spindle running at 100hz (6000 rpm) when RUN is pressed. With these settings, I can change the spindle frequency with the keypad all the way up to 400hz (24,000). When the spindle is stopped PD003 will be set to the frequency that was last set using the keypad (in this example, if stopped at 400 Hz, PD003 would now be set to 400, not 100 anymore). Setting PD003 = 400, instead of 100 initially, has the spindle start up at 400 Hz (24,000) when RUN is pressed.

With this in mind, I chose to start the spindle on my first run at a conservative speed of 120 (7200 RPM) so that I could monitor things. I did not want to first test the spindle at max RPM!

To summarize, on my model, setting PD003 below max (400 Hz) does not limit the keypad from getting max RPM. It only sets the initial Speed 1 when run is pressed (as the manual states) and this setting is changed during constant run with the keypad. Therefore the next time you turn on the spindle it will start at the last setting you selected with the keypad.

Hope that helps!
Take care.

[mactec54]

I'm not sure we have the same model (HY02D223B) or version (Vr1.000). This is not how mine works. P003 does not prevent max spindle RPM if below 400 (max Hz of spindle) when using the keypad. I'm done here now, but as a courtesy, see below if you're interested in the difference between my VFD and the ones you work on regarding PD003's operation.

Again, very much appreciate your help!


This is how PD003 parameter works on the HY02D223B that I have (some of this has already been stated, but for completeness I included it):

First, PD003 applies to the keypad mode only or as the manual says "digital operator mode". Setting PD002 = 1 changes to "external control multi-speed mode" and PD003 is not used.

Using the keypad mode only (PD002 = 0), PD003 must be set between PD005(max Hz) and PD011(min Hz) - in my case 400 and 100 respectively. It doesn't matter if PD003 is 100 or 400, you can still get the max spindle rpm (24,000) using the keypad.

For example, the settings PD002 = 0 (keypad only), PD005 = 400, PD011 = 100, PD003 = 100 will simply result in the spindle running at 100hz (6000 rpm) when RUN is pressed. With these settings, I can change the spindle frequency with the keypad all the way up to 400hz (24,000). When the spindle is stopped PD003 will be set to the frequency that was last set using the keypad (in this example, if stopped at 400 Hz, PD003 would now be set to 400, not 100 anymore). Setting PD003 = 400, instead of 100 initially, has the spindle start up at 400 Hz (24,000) when RUN is pressed.

With this in mind, I chose to start the spindle on my first run at a conservative speed of 120 (7200 RPM) so that I could monitor things. I did not want to first test the spindle at max RPM!

To summarize, on my model, setting PD003 below max (400 Hz) does not limit the keypad from getting max RPM. It only sets the initial Speed 1 when run is pressed (as the manual states) and this setting is changed during constant run with the keypad. Therefore the next time you turn on the spindle it will start at the last setting you selected with the keypad.

Hope that helps!
Take care.

I'm afraid your VFD Drive is no different from what anyone else's has, here is how the KeyPad works and needs to be set to memorize the last speed

You are making it sound like it is different but it is not


(4) When both UP and DOWN terminals are closed at the same time the frequency will neither increase nor decrease. It is regarded as invalid.

(5) When the frequency reaches the max operating frequency it will stop increasing.

(6) When the frequency reaches the min frequency or its lower limit, it will stop decreasing.

(7) After a power breakdown the set value of PD003 will be memorized instead of the frequency.

(8) When using the function of UP and DOWN, the keys of the panel are valid. After changing the values it needs to press SET (ENTER) key for confirmation and then the inverter can implement the action. Meanwhile the value will write to PD003, which will be memorized after a power breakdown.

(9) When keeping pressing UP or DOWN the frequency will increase or decrease rapidly to a point and then increase or decrease at even speed.

(10) The value changed by UP or DOWN can be set through PD077 for confirmation of whether it should be memorized or not memorized. For details refer to PD077.

[justinwol]

Thanks again, I'm still trying to properly understand PD003. If my unit is the same, then I'm missing something as what you have said has not matched with my testing or the manual that I got.

I have a few questions here:

1. What does this mean? What do you mean by "the frequency" as PD003 is the main frequency when PD002 = 0 (keypad mode).

(7) After a power breakdown the set value of PD003 will be memorized instead of the frequency.

On my unit, PD003 is always remembered, whether PD077 is set to 0 or 1. After Cutting power or restarting the spindle, PD003 is set to the last frequency set with the keypad - regardless of whether I press SET or not.

2. I'm not understanding properly how PD003 will prevent the spindle from reaching max RPM. What did you mean by this:

if you use the Keypad only, it must be set at the max main Frequency of your spindle =400Hz to get the max spindle RPM

PD003 setting has no impact on whether I can reach max RPM using the keypad only. So I'm not understanding this point.

3. Are you talking about PD003 limiting RPM when in a different mode? (i.e. "External terminal", PD001 = 1)
As you've explicitly said above "if you use the Keypad only" PD003 needs to be 400 or the spindle won't reach max RPM. This just isn't the case for me. However, maybe your saying that PD003 conflicts with "External terminal" functions? I don't have an analog output yet for Mach3, so I have not and will not be able to do this for some time.

I will primarily be using the pot on the VFD in analog mode (PD002 = 1) for the time being. But you worried me a bit with the statement that it is "best practice" to set PD003 to 400, but I've not understood exactly why or what would go wrong if it wasn't set to 400, because just about all of my testing so far has been done with PD003 set to something other than 400 - because I initially set it to 120 and the keypad changes PD003. I don't want to wreck my VFD!

P.S. Please don't read this in a negative light. I don't want to antagonize you after you've been voluntarily aiding me! I'm only concerned about properly understand my VFD. You are eager to help and I don't want to stop you!

[handlewanker]

Mac.....thanks for enlightening me on the settings of a (my) VFD...…...one statement you did stress and that was NOT to switch the VFD off at the wall socket but on the VFD itself then isolate it at the wall socket when finished.

In OZ we have earth leakage trip devices on the main power supply box that detects any leakage to earth and immediately trips the breaker in the main house supply cabinet.

Would this be interpreted as switching the VFD and motor off by the wall switch while the VFD Is still powering the motor?

At the same time we have had many temporary power outs, some lasting a few seconds, others a hour or more......in South Africa they have power outs practically every day for hours at a time.

Would I be wise to have a UPS on my wall socket where the VFD is plugged in..... (and my CNC mill and computer)…. to continue a supply until I can switch the VFD off manually?....I have one in my study for my CCTV and desktop computer.
Ian.

[mactec54]

Mac.....thanks for enlightening me on the settings of a (my) VFD...…...one statement you did stress and that was NOT to switch the VFD off at the wall socket but on the VFD itself then isolate it at the wall socket when finished.

In OZ we have earth leakage trip devices on the main power supply box that detects any leakage to earth and immediately trips the breaker in the main house supply cabinet.

Would this be interpreted as switching the VFD and motor off by the wall switch while the VFD Is still powering the motor?

At the same time we have had many temporary power outs, some lasting a few seconds, others a hour or more......in South Africa they have power outs practically every day for hours at a time.

Would I be wise to have a UPS on my wall socket where the VFD is plugged in..... (and my CNC mill and computer)…. to continue a supply until I can switch the VFD off manually?....I have one in my study for my CCTV and desktop computer.
Ian.

You GFCI is not a switch for turning something On / Off with, it is a safety device, a regular switch at the wall is fine, Plugging a VFD Drive into a live Plug that can cause a spike and take out the front end electronics so when Plugging and Unplugging a VFD drive the supply Power should be Off

GFCI can present problems when a VFD Drive is used on a Circuit that has this, I don't recommend that you use a circuit that has a GFCI on it, even though that will be code in your country, but saying that if the circuit is rated for the Amps needed then you should not have a problem, the same goes for a UPS I don't recommend anyone use one for a VFD Drives backup Power, it would have to be a monster to be suitable for a VFD Drive and would cost a lot of money

A VFD Drive is normally used in an industrial setting so this is where some of the problems using VFD Drive start to show when used in residential homes workshops, in the NA the 240v supply does not need a GFCI but the 120v supply does

With what you are doing with your VFD Drive you won't have any problems 50Hz 60Hz Parameter settings you can't go wrong the only thing I would be concerned with is the GFCI tripping as a VFD Drive can cause Ground faults so just try and see it won't affect your drive because you are only running at low Frequency

It's only the high Frequency spindle motor 300Hz 400Hz 800Hz Etc that you have to have things setup a little different

If you get any tripping of the GFCI then the first thing would be to add a EMI Power Filter this will help the Power supply noise and better health for the VFD Drive as well this you would install close to the VFD Drive

[handlewanker]

Ah Ha....so it's a spark at the wall switch that you have to prevent by NOT hot plugging in or out a plug...….never done that, and it would be difficult as our plugs really stick in the wall socket tight, and it's highly dangerous too for breaking a circuit.

On the UPS path, the one I have, which is quite modest, is rated to supply for 1 hour 220 volts at 10 amps, so if the VFD needs backing up that would do the trick plenty well.....the motor for the VFD is only 3/4 HP 3 phase......probably 4 amps at most.

We do on occasion get mains spikes from someone switching a heavy load on somewhere down the line, and sometimes the Earth trip does trip out for no apparent reason.

They are fitted as part of the mains supply safety requirement and will trip at 10 Ma leakage to earth .....you can't disable it even if you wanted to.

BTW, on the PD003 VFD thing......reading about the varying speed control in the last post I though the speed was controlled by the round knob on the front....at least mine does...….I won't get into that discussion, just watching to see the outcome.
Ian.

[mactec54]

Ah Ha....so it's a spark at the wall switch that you have to prevent by NOT hot plugging in or out a plug...….never done that, and it would be difficult as our plugs really stick in the wall socket tight, and it's highly dangerous too for breaking a circuit.

On the UPS path, the one I have, which is quite modest, is rated to supply for 1 hour 220 volts at 10 amps, so if the VFD needs backing up that would do the trick plenty well.....the motor for the VFD is only 3/4 HP 3 phase......probably 4 amps at most.

We do on occasion get mains spikes from someone switching a heavy load on somewhere down the line, and sometimes the Earth trip does trip out for no apparent reason.

They are fitted as part of the mains supply safety requirement and will trip at 10 Ma leakage to earth .....you can't disable it even if you wanted to.

BTW, on the PD003 VFD thing......reading about the varying speed control in the last post I though the speed was controlled by the round knob on the front....at least mine does...….I won't get into that discussion, just watching to see the outcome.
Ian.

I would never suggest to anyone to even try to disable a GFCI they are there to help keep you safe

What you can do is run a dedicated line that is not GFCI protected if you have a tripping problem

10 amps may not do the trick if your motor is 4 amps the VFD will be more than double that because you are on single Phase and not 3ph

[handlewanker]

No need to be so down in the mouth Justin.....Mac knows you're confused by this time......just like me.

I just deleted this post and re-wrote it as I think my VFD is different to the one being discussed......possibly it works the same way but I mostly don't understand what is actually being said.....my need is for a 3 phase motor as opposed to a 24,000 water cooled motor.

I'm going by the video on UTUBE by CLOUGH 42 where he very clearly explains with infinite detail the parameter settings on a VFD for a 3 phase motor and why you would want to etc.

BTW....what type of motor is the watercooled 24,000 rpm one you have?....it can't be a brushless one, Mac tells me that you cannot run a brushless motor on a VFD......very understandable...….as far as I know that requires an ESC type.
Ian.

[justinwol]

Well after lots of studying of the manual and testing of the VFD and spindle, I think I've got it sorted. However, I'm not sure you're going to like everything I'm going to write here (be gentle!).

Also, before I get going, just a quick disclaimer: This conversation is centered around frequency settings and operation. It is assumed the other critical parameters are set properly.

The first thing to address is the keypads operation regarding PD003 and PD077:

1. When PD001 = 0 and PD002 = 0, the frequency set by the keypad's UP and DOWN arrows is always memorized to PD003. After a power breakdown, the spindle will start at the frequency set in PD003. Anytime the speed of the spindle is changed with the keypad the operating frequency of the VFD is changed and it is memorized in PD003. I.e. if the frequency is changed with the keypad to 300, it is immediately memorized in PD003.

2. PD077 applies only to UP/DOWN functions of the programmable multi-inputs PD044-PD049 and PD001 = 1 (source of run commands set to "External terminal") and only if a couple of these are programmed to the UP (27) and DOWN (28) functions as they are not programmed to any multi-input terminals by default. In PD077 the manual says, "For the related parameters refer to PD044-PD049." Under the UP/DOWN functions (27 and 28) the manual says that "when the power is up again after the power breakdown the changed frequency will not be memorized." This is because the factory setting for the governing parameter PD077 is 0. As the manual states "When PD077 is set to 0, the changed value will not be memorized and when it is set to 1, the changed values will be memorized. The set values of PD003 will be memorized after restart." This is why setting PD077 to 0 or 1 has no affect on the keypad's operation. With either setting the keypad still sets PD003.

(4) When both UP and DOWN terminals are closed at the same time the frequency will neither increase nor decrease. It is regarded as invalid.

(5) When the frequency reaches the max operating frequency it will stop increasing.

(6) When the frequency reaches the min frequency or its lower limit, it will stop decreasing.

(7) After a power breakdown the set value of PD003 will be memorized instead of the frequency.

(8) When using the function of UP and DOWN, the keys of the panel are valid. After changing the values it needs to press SET (ENTER) key for confirmation and then the inverter can implement the action. Meanwhile the value will write to PD003, which will be memorized after a power breakdown.

(9) When keeping pressing UP or DOWN the frequency will increase or decrease rapidly to a point and then increase or decrease at even speed.

(10) The value changed by UP or DOWN can be set through PD077 for confirmation of whether it should be memorized or not memorized. For details refer to PD077.

These notes are for the UP/DOWN multi-function input terminals programmable functions. They are not for the keypads up and down arrows.

So with keypad use only, setting PD003 in the PRGM menu is only the initial setting. Once the UP and DOWN arrows on the keypad are used to change the frequency of the spindle, PD003 is immediately updated each time. If the multi-function terminals are used and two of them are programmed to functions UP and DOWN, then the operating frequency can be memorized to PD003 (PD077 = 1) each time these terminals are closed to change the frequency. Otherwise if PD077 = 0, the set value of PD003 will be used on restart after power breakdown. However, if PD003 is set below PD011 (lower limit), PD011 overrides PD003 - more about this below. PD077 does not apply to digital operator mode.

Next is the central items to this conversation - PD003 and running the spindle below max frequency.

The "operating frequency" is what sets the speed of the spindle. PD003 is the operating frequency when in digital operator mode or when using the UP/DOWN functions of the multi-function input terminals. The value of PD003 always changes with digital operator mode keypad up and down arrows, but when using the multi-function input UP/DOWN functions, PD003 may stay at a set value if PD077 = 0, or change when these inputs are closed if PD077 = 1.

This is what I don't think you'll like and feel free to tell me to say hello to my new friend, puff the magic dragon: PD003 has nothing to do with the safe operation of these spindles. It is simply the operating frequency of the inverter which is changed through a variety of ways to control the speed of the spindle. These spindles are designed to operate safely within a frequency range. In my case 100-400 Hz or 6000-24000 RPM. Setting the operating frequency outside of this range will damage the spindle over time.

In order to ensure the spindle isn't operated outside its designed frequency range, PD004 is set to the motors rated frequency, P005 is set to the max operating frequency and PD011 is set the lower limit frequency as the manual says, "This is set for preventing workers from false operation to avoid over-heat or some other mechanical faults, which might be caused due to too low operating frequency." PD005 along with PD006-PD010 need to be set with an appropriate V/F curve or damage to the spindle can occur.

Some examples of PD011 overriding PD003. In digital operator mode PD001 = 0 and PD002 = 0, PD011 = 100 and PD003 = 50, when RUN is pressed the spindle spins up to 100 Hz. Likewise, in external terminal mode PD002 = 1, PD003 = 400 (though it is not used here, but set to show it is bypassed), PD011 = 100, PD073 = 50 (lower analog frequency) and the potentiometer turned all the way down (~0V), when RUN is pressed the spindle spins up to 100 Hz and when adjusting the pot on the VFD, the frequency cannot be adjusted below 100 Hz.

In short, PD003 is the operating frequency only and is meant to be controlled through a couple of methods in certain modes. In other modes, PD003 is not used at all, instead the operating frequency is controlled by external sources or communication ports.

Regarding running the spindle below max frequency (400 Hz for my spindle). Unless the VFD is running at max operating frequency all the time (max RPM), the VFD's operating frequency will be routinely less than max and therefore the spindle will be at less than max frequency. This is perfectly safe! This is what these VFDs are designed for in the context of a variable frequency spindle. The only time this is unsafe is when the parameters mentioned above are set incorrectly and an operator is able to set the operating frequency (through whatever method they configured the VFD for) beyond the rated frequency range of the spindle.

I have tested and confirmed all of this and it is all consistent with the manual that I received.

This has been an extremely helpful conversation and I'm very grateful for you engaging with me! You have my respect and thanks.