Refit of old CandCNC Machine

[firepilot]

Ok I got my second Chinese 2.2kw spindle in tonight. I thought I would pull the package if off and see what the readings were from terminal to terminal.

On my old (had a bit of smoke come out of it) with my multi meter set to 2K ohms I had readings of .002 from terminal to terminal except to ground which was nothing.

On the new spindle from a different company the same test yielded readings of .001 from terminal to terminal and nothing to ground.

Not sure if after I get the VFD all set up if I should try to hook the old one up and see if it works.

Anyone have any thoughts on that?

Thank you

Phil

[firepilot]

Well update on the DYN 4 faults. I have now run the drive with the spindle running and I get the same drive fault.

Tonight I swapped the Drive and tried it again. Same result as before. The spindle came up to rpm and the drive faulted. All cables were far away from each other.

I would have to think at this point it is the motor or encoder.

I reached out to DMM this morning but haven't heard back yet.

Good news is I seem to have the spindle running without letting and magic smoke out.

Phil

[martyscncgarage]

Good you have the spindle running ok

You have a noise issue (EMI=Electromagnetic Interference)

First, did you bring all grounds to ONE point? That point would be where the service ground lands? (Not just tying ground wires and drain wires to anything metal)

Did you use VFD cable? That is shielded wire? If so, I would make sure the shield is tied to its ground on both ends. (On the motor AND the VFD, there is debate on this one, but I have read an article from Belden and had a friend that tested the theory with a scope and it seems to work)

Did you use the DMM DYN4 to Acorn cables?

Try this, on the Z axis DYN4 drive. take a ground wire, crimp an insulated eyelet wire connector to it, take a 4-40 screw and secure it to the DB9 nut, then take the other end to the cabinet ground and retest for the issue. The DB25 and DB9 are insulated from ground, presumably for noise immunity.
That is, if you take a DMM and set it to resistance or continuity and put one probe on the plate where the ground screws are and then touch to the plate holding the DB9 and DB25, there is no continuity.

What is in the cable carrier with the Z axis Servo drive cables exactly?
As an experiment, you might pull the servo drive cable out of the carrier and connected it directly to the motor and the drive to see if it makes any difference.

I may have asked this before, but please take and post pictures of the machine, the Z axis head assembly showing the spindle motor, Z axis servo motor, how the cables travel back to the control cabinet and a good high resolution picture of the control cabinet.


I wired up a Phoenix 4'x4' router, it uses a large Porter Cable router motor and DMM 750W motors and its been in service for a couple of years now with no issue like you describe.

You DID swap in a different DYN4 from a different axis and got the same results correct?

Just stuff to try, but I would look at how you grounded everything first.

[martyscncgarage]

I went back through the messages. Your wiring needs cleaning up in the cabinet. I also saw a ground buss with ground wires on it. Is that where your Power feed ground is landed and are ALL other grounds coming back to it? Didn't look like too many ground wires.

Also, I saw a picture of your VFD cable. Did you ground that braided shield on either end, (on the motor and on the VFD and does the VFD have a ground wire going back to that ground buss?

[firepilot]

Will work on wiring again tomorrow. Going to rewire power side with 16ga wire. Currently 12ga but too bulky to organize well. I'm also going to run the Ground from the main feed to the ground buss I have or change the current bar to more terminals and run them together.

Currently the VFD is just on the bench and not grounded to the Control cabinet. I do have one end of the shield wire grounded to the vid but not the motor. I assume I would solder that to the existing ground wire which is soldered to the spindle connector. I did add the ground from the internal side of the connector to the motor itself.

Thanks Phil

[martyscncgarage]

Solder a wire to the shield and ground it.

[firepilot]

Ok. I retired the panel today and I’ll attach a picture.

I believe this is a bit more proper.

I’m the lower part of the picture is the bus bar. I will run the earth ground from the cord/outlet the the bottom of the bar.

The screw attaching the bar Is threaded and tapped into the back plate. The back plate is bolted to the cabinet which is bolted to the aluminum frame of the router.

Grounding the VFD aside is this a good grounding plan?

Thank you

Phil

[firepilot]

Here is the new picture of my panel.

Still on the bench.

Phil

[martyscncgarage]

Here is the new picture of my panel.

Still on the bench.

Phil

It looks ok. The picture is low resolution so coming out from the formum can't see much detail. I can see you followed DMM's drawings to a "T" with all those filters, the reactor and contactors. I use one large contactor to feed the drives. But what you did is fine.
I will be curious to know how you make out with noise.

[firepilot]

Thanks Marty,

I am going to work on is some more today. I will go ahead and run my ground from the power cord to the bar, put it back in the cabinet and see if that improves anything.

When you don't know enough its easier to try and follow directions. Hopefully everything works and we can wrap up the longest build thread in history.

Phil