Hi Andy,

Another suggestion might be to use a small 10Watt switching power supply for KFLOP +5V and mount it a few inches from KFLOP rather than the wall wart plugged in far away with the DC wires running across the VFD.  Maybe another for the encoder +5V?

Have you determined if the problem is caused by a USB communication fault?  Or is KFLOP re-booting?

Regards
TK

 

Andy,

 

Several people have made some excellent observations, that cable leaving the VFD to the Spindle does not appear to be a shielded cable and does not appeared to be grounded on the VFD end.  The second big issue is to try and make all your low voltage wiring is kept clear of the spindle cable.  You are getting EMI interference, no question.  As Greg points out of you have to run the Spindle cable or any AC power cable near lower voltage cable cross it at a 90 degree angle to reduce the amount it can impact the low voltage signals.  You are using a USB isolator which is great as that is another area that killed me in my setup.  If you could put the electronics in a metal enclosure that would also help.  Some people actually put the VFD in a separate metal enclose to help shield the noise. I too have the Hunyang VFD which spews noise like crazy, but I also have an expensive Allen Bradley unit that also caused me issues on the KFLOP until I got all the grounds, shields, and USB isolator in place.

 

Good Luck

 

Russ

 

 

From: DynoMotion@yahoogroups.com [mailto:DynoMotion@yahoogroups.com]
Sent: Tuesday, February 16, 2016 11:07 PM
To: DynoMotion@yahoogroups.com
Subject: Re: [DynoMotion] Need help with a Grounding and/or Noise Issue

 

 

Is the spindle motor cable shielded cable?  You have marked "spindle motor cable shield", is that the shield or the ground.  Either way the wire is way too long and it should terminate at the ground connection on the VFD and be no longer than you need.  The shield (if you are using shielded motor cable) should terminate at both the VFD and the motor, to ground.  How have you terminated the shield at the motor?   Review section D2 in the WJ200 users manual. 

One big no no is it looks like your motor cable is touching one of your encoder/limit switch cables, if not touching it looks to be running parallel to the low voltage cable, also bad.  They should be separated by at least 12" and if they have to cross should cross at 90 degrees.

My suspicion is that the Hitachi VFD uses a higher switching frequency (less audible noise, more RFI noise) than the Chinese POS and is the reason you are having frequent problems.  What is it set to? Parameter b083.  Try lowering it.

Greg.

On 2/16/2016 7:44 PM, andysontag@... [DynoMotion] wrote:

 

Hi All,

 

We've been experiencing a persistent issue that will periodically cause our KFLOP to "go out to lunch". Basically we'll get an error saying there was a read error and then Kmotion and Kmotion CNC will typically be unresponsive. Power cycling the Kflop clears everything up. 

 

Till now we've just dealt with the issue as it only occurred occasionally and restarting the flop, re-homing, and starting where we left off wasn't annoying enough to fix the issue. Although our three year old Huanyang VFD (cheapest/crap VFD ever) finally died and we replaced it with a Hitachi WJ200-022SF. The VFD works great although our KFLOP will now go out to lunch much more often. I actually haven't been able to complete a program as it'll go out just before the real cutting starts. 

 

I'm hoping someone might have some ideas that will make our setup more bulletproof. I've attached a photo that shows our electronics box. I have a few thoughts on what I would probably try to change first, although I figured I might save some time by asking for help rather than guessing and checking. I'm open to trying anything that'll get the job done. 

 

Andy

 

 

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