# "A Man's GOT to Know His Limitations"

… and in my world, 220 volts is the .44 Magnum of electricity. I’ve done the following to get the basic electrical connections in order:

1. Terminated one of the 20 amp 220 volt futures in the garage (Hot1/Hot2/Ground to 20 amp 220 volt breaker (Hot1/Hot2/Ground Bar (not neutral bar). The service is properly grounded to a 10ft deep grounding rod.
2. Attached (plugged in) the VFD to that via a 10ga cable.
3. Made Line to VFD and VFD to Spindle connections according to the following aid:

Before plugging in or turning on the VFD, may I ask that one (or more) of our electrical engineers look at this and let me know if this is going to blow up the spindle and/or VFD, and whether I should give the fire department a courtesy call before proceeding?

Knowing my limitations since the day we were married,

Jim

Hey Jim,

what do you mean with “Hot2”? It should be “Neutral” there.
(EDIT: See post below!)

Also assuming that you refer to the Huanyang VFD, be sure to set “Stopping Mode” PD026 to “1” (Coasting Stop) since it seems you have no braking resistor connected.

Also you don’t seem to have a EMC filter.

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Aahh, wait, just trying to understand how your mains electricity works. If I understand Split-phase electric power - Wikipedia right, you have 120 Volts AC on two phases shifted by 180° and if you want 240 Volts you use the two “Hot” Lines? If yes, then okay, you got to connect a 220 V VFD to two “Hot” Lines.

This seems very strange to non-US people, but it seems to be okay.

We have 3-phase 400 Volts in every house here in Europe and our 230 Volts wall outlets are connected to one Phase (“Hot”), Neutral, and Protective Earth. The three phases are shifted by 120° and each has 230 Volts to Neutral.

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See? It is good to ask. At the moment, I have HOT1 connected to pole 1 of a two pole, 220 volt breaker. HOT2 is connected to pole 2 of the same breaker. I have nothing (on this circuit) connected to the neutral bar of the service. The third, much thinner single strand bare wire is connected to the ground bar of the service/breaker box. Neutral?

The power cable to the VFD is not shielded. The cable between the VFD and the spindle is shielded. The cable that will run to the controller is also shielded. Do I also need a filter? Can you recommend one?

Jim

OK! We’re on the same page for the first half. Filter?

Jim

To be sure, can you measure the voltage (Multimeter on “AC” position) between the two hot, and then between one hot and neutral?

What third, much thinner single strand bare wire?? If you have a single-phase input on the VFD the third wire should be Protective Earth (PE) and not thinner as the others.

Source: Omron MX2 User’s Manual

The Onefinity Controller? Did you connect the RS-485 serial line? You didn’t show this in your diagram.

Does this apply to your mains electricity?

Circuits for lighting and small appliance power outlets (ie. NEMA 1 and NEMA 5) use 120 V circuits - these are connected between one of the lines and neutral using a single-pole circuit breaker. High-demand applications, such as air conditioners, are often powered using 240 V AC circuits - these are connected between the two 120 V AC lines. These 240 V loads are either hard-wired or use NEMA 10 or NEMA 14 outlets which are deliberately incompatible with the 120 V outlets.

Regarding EMC filter, I have chosen the model that is specified in the manual for my specific 200 V single phase / 2.2 kW output VFD model (3G3MX2-AB022-E), this is either AX-FIM1024-RE for a Rasmi model or AX-FIM1024-SE-V1 for a Schaffner model.

Jim did it all work correctly? Is your house still standing?

I hope when you connect your VFD to 220 Volts that you purchased the 220 Volts version!

I also hope that if you have already connected the spindle, that you have previously set the parameters of the spindle in the VFD (according to your spindle manual)?

I do not know which Type of Grounding system you have but anyway, if you have Split-phase electric power with 110-120 Volts between one Phase (Hot) and Neutral, and 220-240 Volts between two phases (Hots), then you should have the VFD (which should be a 220-240 Volts version) connected to the two poles of a 220-240 Volts circuit breaker, nothing to Neutral, and the PE connector or Chassis Ground of the VFD to your Ground.

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Phew. Where to begin?!

First, this IS the system I have. The third, smaller, single strand bare wire is part of this system and not part of the connection between the VFD and spindle. That third wire is, I am pretty sure, the ground or earth wire. So, it seems that the wiring from the main power is correct.

Second, there are four wires of identical gauge coming from an aircraft connector attached to the spindle. These came with the spindle, pre-soldered to the aircraft connector. The wires are numbered 1, 2, 3, and ground/earth. I have extended these wires with wires of the same gauge and these extension wires are assembled within commercially shielded cable. I have connected these extension wires to VFD terminals U,V, W, and G, respectively.

In the US, residential electrical systems that pass the scrutiny of building inspectors are grounded at the service entrance to 10’ long copper ground rods driven into the earth. Within the box that hosts the circuit breakers there is a large copper plate to which each circuit in the house must be fastened. This is the case in my house. The system is properly grounded; thus the connection of the G wire from the spindle, passing through and attached to the G on the VFD, and then to the G terminal of the circuit’s outlet, creates a proper ground/earth connection for both the spindle and the VFD.

I will disconnect the spindle from the VFD before plugging in, turning on, and programming the VFD. Those parameters are clearly outlined in the manual (as clear as translation can make it.) I am feeling confident about the latter.

I have yet to make the connections between the VFD and the Onefinity Controller. I will keep the VFD/Spindle isolated from the controller until it is absolutely clear that the VFD/Spindle are assembled and operating correctly. Thanks for the info on the filter.

Jim

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Hey Jim,

sounds good. I find everything correct.

EMC Filter is optional.

Yes, wiring the RS-485 to the Onefinity Controller can be done later.

What manual do you have?

Thanks! It is an HY Inverter manual for the HY03D223B 2.2KW 10 Amp inverter/VFD.

Jim

Do you have a manual for your spindle?

It’s a print version. The spindle did not come with a manual. There is no brand name on it either. The vendor came highly recommended here, and the online description showed runout of <.001. It is Chinese, I am sure. As mentioned in another post, though, I am loathe to criticize the quality of Chinese products since a great deal of the machinery in my woodshop was made in China and runs really well.

Jim

Hey Jim,

if you don’t have a spindle manual, you’ll have to know at least a few facts in order to set the settings right. You bought this spindle, right?

You need to know the minimum and the maximum RPM. This will allow you to deduce the number of magnetic poles. If it’s a max. 24,000 RPM spindle it is likely that it has 2 magnetic poles (= 1 pole pair). PD143 (Motor Pole Number) is often factory-set to 4 poles which would be wrong then.

The max frequency the Huanyang VFD offers is 400 Hz. The spindle RPM is calculated this way:

SPINDLE_RPM = \$VFD_FREQ × 2 × 60 / \$SPINDLE_NUMBER_OF_POLES

Mostly it will be max. 400 Hertz × 2 × 60 / 2 poles = 24,000 RPM.

So you may set the max. and the base frequency to 400 Hz.

If the minimum speed is 8000 RPM I would not run it slower. My spindle’s manual states clearly that the VFD must be set not to allow it to run slower. I have no experience with the Huanyang VFD but according to the manual I would say this is PD011 (Frequency Lower Limit). 8000 RPM would mean 133 Hz.

Also you should know what the current rating of the spindle is. This allows you to set the VFD to protect the spindle from overcurrent. With your VFD model which is a 2.2 kW model it should be preset at 11 A. This would be okay for a 220 Volts 2.2 kW spindle. However if you drive a 1.5 kW spindle on this VFD I would set it to 7 A (PD142, Rated Motor Current).

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Min/Max RPM = 8000/24000
PD143 needs to be set to 2 poles
400 Hertz is correct for Max/Base, PD011 will be set to 8000 RPM or 133 Hz.
PD142 will be set to 6.82 amps (Or 7 if it doesn’t get that granular.

Thank you SO MUCH!

Jim

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Aiph5u,

I found a link to a PDF of the manual. It is here, way down at the bottom left of the page, if you want a copy:

There is some far less detailed information on the spindle at the bottom of the page here:

I’ve adjusted all the parameters on the VFD and am about to plug in and turn on the spindle. If you read about a nuclear explosion in Northern WI, you know what happened. At least it will be a quick way to go!

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Hey Jim,

yes, I’ve seen it already, that Huanyang manual is identical to the version they have at buildbotics. You posted the link for the spindle in another thread already, these were the links I consulted for being able to help you.

Regarding international mains electricity, I’m learning too (see above)

a “go” from here

Good luck!

Not a Go. Spindle immediately accelerated to 400Hz. Got very hot within moments. Potentiometer (PD set to “0”) did not work. I don’t think I fried the spindle, but I won’t proceed until their engineer calls me back. If no help, this set is going back and I’m going to get a pre-wired Mechatron.

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400 Hz is an allowed frequency for the spindle.

Jim you did not show all the settings you’ve done.

Enabling the potentiometer should be done by setting PD002. To which value did you set it?

The setting at PD002 is “0”. The rest is right off of the “cheat sheet” their engineer sent me - with the exception of the changes you and I have corresponded about. Their cheat sheet is for a 2.2kW spindle. PD143 is set to “2”. PD011 is set to “8000”. Voltage is set at 220 and current (PD142) at “7.”

Here’s the cheat sheet provided by the vendor’s engineer:

Variable speed

PD000=0 for Parameter unlock ( 1 ) for Parameter Lock

PD001=0 (1 For Remote Control)

PD002=0 ( 1 For 0-10v Terminal Control or Remote Trim Pot Control )

( J1 Also Needs to be set for Terminal Control)

PD003=400

PD004=400

PD005=400

PD007=20

PD008=220 (Motor Rated Voltage, If you have 120v spindle then set to 120v )

PD009=15

PD010=8

PD011=120 ( 100 Minimum Setting with Quality VFD, 120 is Safe)

PD13= 08 is for Factory reset, Only use this to set VFD to Factory Default SettingsPD014

Acceleration = 12 ( Adjust to suit)

PD015 Deceleration=12 (Adjust to suit) ( PD15 is ignored IF PD26=1 Then the Spindle will

Coast to a Stop)

PD141=220 ( Motor Rated Voltage ) (120 for VFD Rated for 120v )

PD142= ( Motor Max Amps) PD142=( 220vSet for your motor Amp Rating 2.2Kw Spindle

9 amp )

PD142=( 220VSet for your motor Amp Rating 1.5Kw Spindle 7 amp )

PD142=( 220v Set for your motor Amps Rating 800w Spindle 4 amps )

PD142=( 120v Set for your motor Amp Rating 800w Spindle 7 amp )

PD143=2 ( Motor Number of Poles)

PD144=3000 (Max Motor RPM) =3,000= (24,000)

PD70=0 ( This may need to be set to 1 if Control Voltage is 0-5v ) I DID NOT CHANGE THIS

PD72=400

PD73=120 ( 100 Minimum Setting )

If you have E. Lv. S error code alarm I DID NOT ALTER ANY OF THE FOLLOWING

Pls set

PD200=65535

PD209=70

Weight: 3.3IBs

Width 5" X Length 6.75" Height: 6.375"

This is what one gets for being “penny wise and pound foolish.”