Huanyang VFD and Pump Wiring Diagram Review

[Shwerk (Josh Workman)]

Good evening, all.

I just ordered an Elite Journeyman a couple of weeks ago. I’m going to run it with a Huanyang 220V 2.2KW Spindle.

I was hoping to get some feedback on my custom wiring diagram for my Huanyang VFD. I have a bunch of questions about it (written on the diagram and copied below).

• Is the “stop” signal that is sent from Masso to the VFD when the Masso E-stop is pressed safe enough? Or should the ‘ES’ TTL signal from Masso be wired to a VFD input as an emergency stop signal?
• Is a GX12 connector (cable side) included with the Onefinity kit?
• What type of cable is recommended for the signal lines from the Onefinity GX12 spindle connector to the VFD? How many conductors? Any fancy shield or termination?
• Right now the Masso controller has no way of knowing if the VFD is in a fault state. Is that a problem?
• For the power cord from the NEMA 14-30R wall outlet to the VFD, can the cord be made out of the same 16AWG 3+PE cable used for the VFD to spindle cable? Will the neutral (W) line need to be tied to anything or should it just be terminated in a wire nut?
• Is the EMI filter before the VFD recommended/necessary if the VFD is the only load on that circuit and it is wired with double shielded cable?
• If I switch to a better 110V pump in the future, would I simply need to swap the ‘220V Hot L2 (Y)’ with the neutral line ‘W’?
• What would be the best way to power the flow sensor: 24V from the Onefinity Power Supply, 24V from the Masso, 24V from the HY VFD, or 24V from a separate power supply?
• Any typos?

Also, if you have any questions or suggestions, I would love to hear them!

Thanks,

Josh

[Aiph5u (Aiph5u (not affiliated with Onefinity))]

Hey Josh,

an emergency stop button shall not interrupt the power of a VFD. The only way to stop a spindle, including emergency stop, is to use the STOP mode of the VFD (either through front keypad, modbus command, or programmable input terminal with STOP function assigned to it). Some VFDs additionally have an emergency circuit support, like Omron MX2. See VFD manual. According to the updated IEC 60204-1, a VFD’s spindle STOP command is considered as a valid Safe Torque Off (STO) that fulfils the stop category 0 requirement (so allows to e.g. safely manually change the tool in this state).

@Aiph5u

As of updated IEC 60204-1, an emergency power cutoff is only recommended if it is absolutely necessary. One such case would be a fire, when you would cut all the power in case of fire with a big paddle switch at the door, so that the firefighters can be sure there is no electricity present anymore. In this case, you would cut everything with the paddle switch, not only a VFD, but both the CNC controller and the VFD and everything.

In all other cases, it is an emergency stop of all motors and acutators that is wanted instead, with Safe Torque Off (STO) as final state. A VFD needs to remain powered on to reach this state.

I know of no useful setup where a CNC controller would cut the power to a VFD. A CNC controller should be able to send the VFD a Safe Torque Off (STO) which is both possible via ModBus or via VFD input terminal like the Masso CNC controller uses.

According to the updated IEC 60204-1, a VFD’s spindle STOP command is considered as a valid Safe Torque Off (STO) that fulfils the stop category 0 requirement.

A category 0 or 1 stop safety circuit has to be wired in a way that after the Emergency Stop has been triggered, the setup cannot be restarted again without having pressed a dedicated RESET button. Therefore for an emergency circuit, you use a (ISO 13849) Safety relay such as a Omron G9SE. See here for a circuit diagram that describes how to wire it.

That’s why on VFD control cabinets, you have usually in the front door:

1. A manual power switch (can be a magnetic contactor that will prevent to be on when power comes back after a power outage) for powering up the entire setup. Don’t cut power to the VFD when the VFD is not in STOP mode!
2. A red/yellow mushroom-shaped Emergency Stop switch that is wired to the safety relay circuit, that will lead to a Safe Torque Off (STO) of all motors and actuators of the entire CNC machine
3. A reset pushbutton without which it is not possible to restart the motors and actuators of the system after Emergency Stop was triggered.

You can see these three components in the back of the door:

@Aiph5u

you can buy a control cabinet assembled and configured ready-to-use:

• Electrical Cabinets - Mechatron

Unboxing video:

CNC Finale: Automatic Toolchanger Spindle Install & Testing

Image: Shown is a full-blown control cabinet with VFD, circuit breaker, safety relay (red), and EMI filter on the left, and the pneumatics system for the automatic tool changer system of the ATC-8022-42-HSK25 2.2 kW 42,000 rpm water-cooled spindle on the right (and additional air tube (blue) with valve retrofit by video author which also wanted workpiece mist coolant – described in the video). On the back of the door you see the back of power switch, emergency button and reset button. Note the thick earth line that connects door to the rest of the cabinet.

@Shwerk

Is a GX12 connector (cable side) included with the Onefinity kit?

No, but a ready-to-use cable is available, see link to GX-12 below.

@Shwerk

What type of cable is recommended for the signal lines from the Onefinity GX12 spindle connector to the VFD? How many conductors? Any fancy shield or termination?

For signal cable cross-section area, see VFD manual.

For GX-12 VFD control cable pinout and sources, see here:

• Masso Elite VFD control cable

@Shwerk

For the power cord from the NEMA 14-30R wall outlet to the VFD, can the cord be made out of the same 16AWG 3+PE cable used for the VFD to spindle cable? Will the neutral (W) line need to be tied to anything or should it just be terminated in a wire nut?

If you use a VFD with single-phase AC input (which is the case if you have 110/220 V split-phase electricity), you need a 2+PE cable. If you use a VFD with single phase AC input on your VFD, the single-phase input current is about 2.5 x higher than the three-phase spindle output current, thus requiring a cable sufficient for such current. Remember a VFD is an AC-to-DC-to-three-phase-AC inverter. See input current specification of your VFD:

@Aiph5u

Images: Here you can see the nameplates of two 220 V VFDs for single-phase input for a 2.2 kW motor. As you can see, the max. input current is 24 A, which would require a 2+PE power supply cable of 6 mm² cross-section area (AWG 10), at least 4 mm² (AWG 12).

@Aiph5u

Usually you will need 2+PE if your VFD is made for single phase input, and for spindle output you will need shielded 3+PE for the three phase spindle. Cables especially made for drag chains are e. g. LAPP ÖLFLEX® CLASSIC FD 810 CY or IGUS chainflex® .

As for choosing the wire’s cross-section area (or diameter aka gauge ), it is dependent on current (i.e., ampères ).

In my VFD manual, it says:

– Source: Omron MX2 User’s Manual

Note that this table contains an error. For the VFD for 2.2 kW motor with single phase input, you don’t need 6.3 mm² / 10 AWG on the three-phase spindle output, 3.3 mm² / 12 AWG is enough there (remember the three phases are shifted by 120° to each other). The 6.3 mm² / 10 AWG cable is only required on the single phase input (from NEMA 14 socket to VFD input) of the VFD.

Note that there is no absolute wire cross-section area for a specific current. wire cross-section area is calculated with a formula that includes cable length and efficiency loss. So if you choose a smaller cross-section area than recommended, you will loose some power that is transformed into heating the cable. Usually you dimensionate a motor cable in a way that your loss is to neglect and that the cable does not get hot.

Note that if you use 115 Volts, for the same power (kW/HP) double the amperes than with 230 Volts do flow and therefore you will need wires with the double cross-section area then.

• See also: Comparison chart of AWG (blue), SWG (red) and IEC 60228 (black) wire sizes (hover mouse over a field to see dimension)

On the VFD input side, if you use 230 V from split-phase electricity, you only use the two hots. You need a 2+PE cable for this. The neutral is only necessary to grab a 115 V suplly if you need it.

On the VFD output side, there is no neutral, as there is no neutral on a spindle. The wires are U, V, W and PE, and shield. See here

@Aiph5u

What is crucial for safety in a spindle motor cable is the fourth wire, which is the protective earth (PE) wire! Never should one connect a spindle without this wire that should be connected to VFD ground (⏚) and the VFD grounded in a grounded wall outlet.

@Aiph5u

@Aiph5u

You will need shielded 3+PE cable for the three phase spindle. Cables especially made for drag chains are e. g. LAPP ÖLFLEX® CLASSIC FD 810 CY or IGUS chainflex®.

I use LAPP ÖLFLEX® CLASSIC FD 810 CY , in the strength 4 x 2.5 mm² (LAPP #0026271) for the 2.2 kW spindle or 4 x 1.5 mm² (LAPP #0026251) for a 1.5 kW spindle (=shielded 3+PE ).

@Aiph5u

• On the output of the VFD, i.e. the spindle cable, you should use shielded 3+PE for the three-phase spindle, like shown here:

Image 1: A typical spindle cable for use in a power chain (LAPP ÖLFLEX® CLASSIC FD 810 CY )

See this thread for more information.

@Aiph5u

Note that even if PE wire and cable shield are both connected to ground, they serve two different purposes. PE is crucial for electrical safety, and shield cannot replace the PE wire!

Therefore the reference to “16/3” in the topic’s title is dangerous: NEVER connect a spindle without a PE wire ! Shield cannot replace a PE wire!

@Shwerk

Is the EMI filter before the VFD recommended/necessary if the VFD is the only load on that circuit and it is wired with double shielded cable?

An EMI filter is the most recommended accessory for a VFD. Be sure that the EMI filter is made for the VFD rated input current (here: 24 Ampères in the example above for a 220 V VFD for 2.2 kW spindle. An underdimensionated EMI filter is dangereous because the current constantly flows through its capacitors, so they have to be rated for that current.

Note that many cheap no-name / Huanyang spindles simply omit the VFD input current specification both on their nameplate and VFD manual. See Incorrect or missing data on cheap chinese VFDs and spindles for details.

@Shwerk

If I switch to a better 110V pump in the future, would I simply need to swap the ‘220V Hot L2 (Y)’ with the neutral line ‘W’?

If you have split-power electricity as is common in North America domestic areas, 230 V ist between two hots and 115 V is between one hot and neutral.

@Shwerk

What would be the best way to power the flow sensor: 24V from the Onefinity Power Supply, 24V from the Masso, 24V from the HY VFD, or 24V from a separate power supply?

Usually you have a 24 V supply like Meanwell MDR10-24 or a MDR20-24
in your VFD control cabinet to drive the safety relay etc. (e.g. Omron G9SE). Using a separate power supply like this avoids concern about how the 24 V is connected to other things.

[Shwerk (Josh Workman)]

Good point. If I had the money I’d buy a Datron, but I’m pinching every possible penny. I’d like to, if possible, get away with powering the flow sensor off of an existing 24V supply. But I agree thoroughly that a separate supply would be best.

I think I’ll tie the flow sensor into the Masso’s 24V since that will reduce wiring length and complexity. The 5-24V sensor I’m looking at will only draw a maximum of 10mA at 5V, so it should be roughly 2mA at 24V if Ohm’s Law still applies in this lawless world.