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1.5/2.2kW Spindle and VFD

BUN-SPIN-1500-AIR-ER11-00-BD600-1

Safety Statement
The author of this document is not liable or responsible for any accidents, injuries, equipment damage, property damage, loss of money or loss of time resulting from improper use of electrical or mechanical or software products.

Assembling electrical and mechanical machine components like power supplies, motors, drivers or other electrical and mechanical components involves dealing with high voltage AC (alternating current) or DC (direct current) and other hazardous items which can be extremely dangerous and needs high attention to detail, experience, knowledge of software, electricity, electro-mechanics and mechanics.

BEFORE MAKING ANY CONNECTIONS OR DISCONNECTIONS POWER MUST BE REMOVED FROM THE DEVICE AND THE CONTROLLER. FAILURE TO DO SO WILL VOID ANY AND ALL WARRANTIES.

Before starting please read through all the instructions.
Note: Any Mains power connections must be installed by a Licensed electrician or suitability qualified person.

All Errors and Omissions Excepted - feedback is, of course, welcome!

1.0 Introduction

This guide is for wiring and programming the 1.5kW/2.2KW Air-Cooled or Water-Cooled Spindle while using the Folinn VFD.
This guide will also cover the following control approaches:

  • Spindle control via the panel on the VFD using the in-built potentiometer
  • Spindle Control via software using the 0-10V Analog input on the VFD

 

Click on the button below to view the manufacturer’s manual of BD600 series AC drive

Read through all information below before starting any wiring or programming. Verify continuity using an Ohms meter if the outer case on your spindle is electrically bonded to Pin 4 (earth/ground). If the spindle is not bonded to pin 4 we recommend adding a bonding wire.

Please do not attempt to run the Spindle without first adjusting the VFD parameters or you may irreversibly damage the spindle. Spindles damaged by an incorrectly programmed VFD may void your warranty.

DISCLAIMER: Mains connections are to be done by a licensed electrician or suitably qualified person, always ask for a COES. Thoroughly read through the manual provided with the VFD and understand the function of the parameters before running the spindle. VFDs are complicated electronic devices and will be damaged or dangerous if not wired and configured correct. When in doubt, get a suitably qualified person to install and program. Critical parameters and the recommended settings are outlined in this guide, however again please also do your own research and read the manual thoroughly. Never make any connections or disconnections when any device is energised. Best practice is to physically unplug any electrical device from the wall when doing any electrical work.

NEVER WORK ON A LIVE CIRCUIT.

It is always best to use crimped connectors when terminating to the VFD, and to solder the wires to the terminals of the Spindle. Always use heat shrink to cover all connections to protect against short circuits.

2.1 Folinn VFD Wiring

Mains Connection: Use a cable suitable for 10A 240V
  • R = Active
  • S = Neutral
  • T= Nothing
  • Earth = Earth

2.2 Spindle Connection

Best practice is to melt a small amount of solder in the connector pin before terminating the wire. Cut to length and tin the end of your cable. Then solder the cable to the terminal and ensure it is making a solid connection. Heat shrink all connections once complete.

 

Screenshot 2022-12-13 150714

Please note, if your spindle spins anti-clockwise then simply swap U and V on the VFD to make it spin clockwise.

Earth/Ground Terminal Symbol

3.0 VFD Parameters: Folinn BD600 – 1.5/2.2kW VFD

Click to expand

Initially Reset the VFD to factory default setting settings by setting F00.28 = 1. (See below on how to change the parameters)

  1. To begin programming, press the PRGM/ESC button and the programming parameters will show the parameter menu. With a new VFD out of the box, it will be F00.
  2. Press the FUNC/DATA button to enter the F00 parameter menu. It will now Show F00.00. Use the up and down arrows to change the parameter to read F00.28. You can also use the JOG button to shift to the right for parameters with multiple digits.
  3. Press the FUNC/DATA button to view and change the current value. By default, it should be 0. Change it to 1 by pressing the up arrow once.
  4. Press FUNC/DATA again to set and save the parameter. When all the parameters have been set, press the PRGM/ESC button to leave the programming menu.

There are two ways to control the VFD; 

  • For control via potentiometer go to section 3.1

  • For control via software go to section 3.2

3.1 VFD Parameters: Potentiometer Control:

If you are controlling the VFD via potentiometer, follow the above steps and use the following parameters  

  • Frequency Reference Resolution
    • F00.11 = 1
  • Speed Control Mode
    • F00.00 = 2
  • Command Source Selection
    • F00.01 = 0
  • Max Output Frequency
    • F00.03 = 400.00
  • Run Frequency – Upper Limit
    • F00.04 = 400.00
  • Run Frequency – Lower Limit
    • F00.05 = 133.00
  • Frequency A command selection
    • F00.06 = 10
  • Keypad Setting Frequency
    • F00.10 = 400
  • Acceleration time 1
    • F00.12 = 5
  • Decceleration time 1
    • F00.13 = 5
  • Motor Rated Power: (Ensure that you choose the correct motor power rating for your spindle)
    • 1.5kW: F02.01 = 1.5
    • 2.2kW: F02.01 = 2.2
  • Motor Rated Frequency
    • F02.02 = 400
  • Motor Rated Speed
    • F02.03 = 24,000
  • Motor Rated Voltage
    • F02.04 = 220
  • Motor Rated Current: (Ensure that you choose the correct motor current for your spindle)
    • 1.5KW: F02.05 = 7
    • 2.2kW: F2.05 = 9

If you wish to change the VFD display from Frequency (Hz) to RPM, use the following parameters

  • VFD Display RPM
    • F07.03=0011

  • Decimal Points for Speed Display
    • F07.12=0

End of Procedure.

3.2 VFD Parameters: CNC 0-10V Control:

If you are controlling the VFD via software, follow the instructions in section 3.0 and use the following parameters. These parameters are for control of the BD600 VFD via the xPRO, E5X MCS, AXBB-E or other motion controller with a 0 – 10V analog output.

Initially Reset the VFD to factory default setting settings by setting F00.28 = 1

  • Frequency Reference Resolution
    • F00.11 = 1
  • Speed Control Mode
    • F00.00 = 2
  • Command Source Selection
    • F00.01 = 1
  • Max Output Frequency
    • F00.03 = 400.00
  • Run Frequency – Upper Limit
    • F00.04 = 400.00
  • Run Frequency – Lower Limit
    • F00.05 = 133.00
  • Frequency A command selection
    • F00.06 = 2
  • Keypad Setting Frequency
    • F00.10 = 400
  • Acceleration time 1
    • F00.12 = 5
  • Decceleration time 1
    • F00.13 = 5
  • Motor Rated Power: (Ensure that you choose the correct motor power rating for your spindle)
    • 1.5kW: F02.01 = 1.5
    • 2.2kW: F02.01 = 2.2
  • Motor Rated Frequency
    • F02.02 = 400
  • Motor Rated Speed
    • F02.03 = 24,000
  • Motor Rated Voltage
    • F02.04 = 220
  • Motor Rated Current: (Ensure that you choose the correct motor current for your spindle)
    • 1.5KW: F02.05 = 7
    • 2.2kW: F2.05 = 9

If you wish to change the VFD display from Frequency (Hz) to RPM, use the following parameters

  • VFD Display RPM
    • F07.03=0011

  • Decimal Points for Speed Display
    • F07.12=0

End of Procedure.

3.3 VFD and xPRO V5 – Wiring Diagram

Please wire your VFD’s terminals and xPRO V5 controller as shown below

analog_vfd-bd600-2
Click to expand

xPRO V5 Controller Terminals Folinn BD600 VFD Terminal
GND (TOOLHEAD PLUG) ACM
0-10V (TOOLHEAD PLUG) AI1
GND (Relay) ACM
NO (Relay) S1

Ensure to connect ACM to DCM as per wiring diagram above.

After making the necessary connections and programming the VFD, You must calibrate the xPRO Controller to output the correct signal using the onboard potentiometer.

Referencing the image above, please follow the steps below.

  1. Make sure that the TOOLHEAD switch is in the PWM Position indicated by the #1 arrow.
  2. Remove the 4 screws holding the xPRO V5 lid and locate the 0-10V potentiometer indicated by the #2 arrow.
  3. Open up CNCjs and connect your xPRO V5 via USB. Connect the 24V power supply and switch the xPRO V5 controller on.
  4. In the CNCjs console, enter the following commands:
  5. $Spindle/Type=PWM
  6. $32=0
  7. $GCode/MaxS=24000 (Sets spindle Max Speed)
  8. $GCode/MinS=8000 (Sets spindle Minimum Speed)
  9. Next enter M3S24000. Your spindle will turn on so please ensure that the collet nut is removed.
  10. Put the probes of your multimeter on the GND and 0-10V terminals on the TOOLHEAD terminal and adjust the 0-10V potentiometer until the multimeter reads 10.00V.
  11. Type in the console M5 to turn the spindle off.

3.4 VFD and AXBB-E – Wiring Diagram

The AXBB-E can output a 5 or 10V output signal and by default, it is configured for 10V signal output.  For the BD600 VFD, a 10V signal is required and as the 10V signal is already set by default, no extra calibration is required. 

To control the Spindle and VFD via the AXBB-E, please follow the guide below. Note that this guide is for the BD600 VFD with 0-10V input.

Please wire your VFD’s terminals and AXBB-E controller as shown below

AXBB-SPINDLE-BD600-2
Click to expand

After wiring the VFD as above, the final step involves using a piece of wire to bridge ACM and DCM pins together, on the terminal strip pins shown by the red arrow.

Ensure to connect ACM to DCM as per wiring diagram above.

Credits

Special thanks to:

  • The Open Source Hardware Community.
  • Our fantastic customers, whose feedback constantly helps us improve our design.
  • The Folinn VFD 1.5 kW (BD600 Series) can be purchased via this link
  • The Spindle Bundles can be purchased via this link.
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