Integrating Sunfar E550 with Acorn PLC

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martyscncgarage
Posts: 6687
Joined: Tue Mar 28, 2017 12:01 pm
Acorn CNC Controller: Yes
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CNC12: Yes
CNC11: Yes
CPU10 or CPU7: Yes
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Location: Mesa, AZ

Re: Integrating Sunfar E550 with Acorn PLC

Post by martyscncgarage »

Upnorth wrote: Fri Nov 13, 2020 6:16 pm I had weird issues with that exact VFD. A sunfar 550. I had a lot of electrical noise issues. Random estops. Drawbar software crashes. Other miscellaneous problems. I put in a GS-2 VFD from Automation Direct and all the issues went away.
I like Automation Direct GS2 and GS3 drives. I have tried and had good luck "So Far" with TD200 series drives from Factorymation.com as well.
On my 4th one now.

Marty
Reminder, for support please follow this post: viewtopic.php?f=20&t=383
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Mesa, AZ
Arthur
Posts: 11
Joined: Sat May 16, 2020 12:09 am
Acorn CNC Controller: Yes
Allin1DC CNC Controller: No
Oak CNC controller: No
MPU11 & GPIO4D -w/ 3rd Party Drives: No
DC3IOB: No
CNC12: Yes
CNC11: No
CPU10 or CPU7: No
CNC Control System Serial Number: A81087C2F400-0530192077

Re: Integrating Sunfar E550 with Acorn PLC

Post by Arthur »

Upnorth wrote: Fri Nov 13, 2020 6:16 pm I had weird issues with that exact VFD. A sunfar 550. I had a lot of electrical noise issues. Random estops. Drawbar software crashes. Other miscellaneous problems. I put in a GS-2 VFD from Automation Direct and all the issues went away.
Thanks for your input. I am leaning towards replacing my VFD, just waiting for last word from it's manufacturer. Apparently it has a defective input circuitry.

Best,
Arthur
Arthur
Posts: 11
Joined: Sat May 16, 2020 12:09 am
Acorn CNC Controller: Yes
Allin1DC CNC Controller: No
Oak CNC controller: No
MPU11 & GPIO4D -w/ 3rd Party Drives: No
DC3IOB: No
CNC12: Yes
CNC11: No
CPU10 or CPU7: No
CNC Control System Serial Number: A81087C2F400-0530192077

Re: Integrating Sunfar E550 with Acorn PLC

Post by Arthur »

Update on my troubleshooting incase if any one wants to pick thing or two from it.

Sunfar E550 VFD Ai (analog input) test conducted.

Test #1

Disconnected analog speed control cable from Sunfar E550 VFD and connected Acorn PLC speed control output to DMM.

Note: X1, X2, X3, X4 & CM terminals connected to Acorn PLC Outputs via relay circuitry
F0.00 parameter set to 1, F0.02 set to 1001

1. Set spindle speed on CNC12 VCD to 24000 RPM, clicked on Spindle Cycle Start button and DMM reading was 10.1 Volts.
2. Reduced spindle speed on VCD to 20000 RPM – reading was 8.01 Volts
3. Reduced spindle speed on VCD to 15000 RPM – reading was 6.1 Volts
4. Reduced spindle speed on VCD to 12000 RPM – reading was 5.02 Volts
5. Reduced spindle speed on VCD to 6000 RPM – reading was 2.4 Volts

This test confirmed that Acorn PLC is functioning properly and adjusts voltage on analog speed control terminal according to my calculations 10 Volts : 24000 RPM = 0.00041 Volt/Rev.

Test #2

Disconnected analog speed control cable from Acorn PLC and applied 3.7 V DC using rechargeable battery to Ai input of Sunfar E550 (negative lead to the ground and positive to Ai terminal) Spindle span at considerably lower RPM instead of calculated 9000 RPM (3.7v/0.00041) and the display reading of D-0.7 parameter on Sunfar E550 was 18.5

The jumper of Ai input terminal was set to V position.

Test #2 Proved that Sunfar E550 VFD is not reacting to speed control value supplied by Acorn PLC therefor determined to have faulty Ai input circuitry and it introduces some sort of variable frequency (45kHz 125kHz 250kHz) electrical noise into Acorn PLC causing convulsive Y-master and slave Axis movement.

Otherwise, Sunfar E550 works fine controlled by its keypad.
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