HY SERIES VFD AND BLACKBOX SET-UP OPTIONS

HY VFD AND BLACKBOX SET-UP OPTIONS

This document started out as my bench testing notes when I set up my 1.5kw 220v 2400rpm 400hz air cooled spindle and a Huanyang HY series 2.2kw inverter. I think that the HY manuals contain all of the info needed but the translation to English is hard to understand. So I have included my translation of the functions and parameters where I am confident their meaning. I am sharing this in the hope it will help others.

The line voltage wiring is pretty well covered in the manual so I am not planning on covering that here.

Note, some settings cannot be changed in the RUN mode! I’m going to mention this a couple of times because it messed me up. I would also suggest making all wiring and jumper changes with the unit disconnected from power.

Setting VFD parameter PD013=8 will reset all parameters to factory defaults. I suggest this as a first step because the parameters I list below are the only ones I touched. All other (not noted) parameters on my working set up are factory defaults. YOU NEED TO BE STOPED TO HAVE PROGRAMMING CHANGES TAKE EFFECT.


BASIC MOTOR SETTINGS
The VFD needs to be set to the specific electrical parameters of your spindle. You need to set these before you connect the motor to the VFD. The values shown below are for my spindle, so you must verify parameters of your spindle and make the substitutions as necessary.

PD005 = 400 enter the max frequency of your spindle.
PD004 = 400 enter the base frequency of your spindle. You need to set PD05 first.
PD006-010 These parameters define the torque curve, I used the default settings.
PD014 = 5 Acceleration (spin up) time in seconds test to verify
PD015 = 5 Deceleration (spin down) time in seconds test to verify
PD141 = 220 enter the max rated voltage for your spindle. The manual says to enter 220 for the 230v class inverter.
PD142 = 7 enter the max rated amps for your spindle
PD143 = 2 Number of motor poles, I was unable to confirm this with my spindle supplier. My understanding from research is that this is going to be 2 or 4 mine works at 2.
PD144 = 3000 Rated motor revolution. I was unable to confirm with supplier, but a few others suggest they have this set to 3000. With this set to 3000 my spindle runs at a max speed of 24,000rpms.


MANUAL CONTROL
With the basic settings made you can connect and manually operate the spindle from the front panel buttons of the VFD. I feel like this is a good first step to go thru to verify that everything is working. This is also a good procedure to test that you spindle is spinning the proper direction and speed.

VFD Parameters for manual control
PD01 = 0 this uses the up/down arrows to set the output in hz.
PD02 = 0 this set the onboard operator arrows to control speed
PD03 = 150 Main Frequency, this is the frequency that the spindle will run in the operator mode. You can change this with the arrows. With this set to 150 you will get 9000rpms when you hit run from the operator panel. I think this value is calculated like this 150hz X 2peaks X 60sec = 1800 / 2poles = 9000rpms. THIS VALUE IS MEMORIZED WHEN YOU SET IT WITH THE ARROWS FROM THE FRONT PANEL.


OPTION TO USE ONBOARD POTENTIONMETER
If desired you can use the onboard dial to set the spindle speed and use the stop and run keys will stop and start the spindle.

Verify that on board jumper set to VR, this is the default position. Jumper is located to the right of the low voltage terminals.

PD002 = 1 this set the source of operating frequency to the board pot
PD070 = 1 0-5v
PD072 = 400hz
PD073 = 150hz this will set a min speed of 9000 rpms

OPTION FOR 0-10 OR PWM SPEED CONTROL
This gives you control of the spindle from just a 0-10 volt signal. It seems like this is the option that most people use, and are happy with. For me there were a few things I did not like about this config, I will detail these things below.

Set all parameters from 'BASIC MOTOR SETTINGS'
You could use 0-10 or PWM to control the speed of the spindle just see the options described below. I found the PWM resulted in a slightly more accurate speed setting.

Connect the low voltage wiring as follows.
From the blackbox wire the toolhead GND to the ACM terminal on the VFD.
From the blackbox wire the toolhead 0-10 to the VI terminal on the VFD. OR you could use PWM to VI. I used a shielded cable for this, the drain is connected to ground on the VFD side.



You need to install a switch or jumper wire between the VFD terminals marked FOR and DCM. I feel it would be smart to connect a switch here rather than a jumper. Closing this connection tells the VFD to run at the speed given by the VI terminals, but not less that the min freq defined by PD011. This connection does lock the VFD in the run mode, keep this in mind. If you press the stop you will need to open and close this connection or power cycle to restart the spindle. Also, this connection needs to be open when making some programming changes.

You need to set the VI/VR onboard jumper on the VFD to the VI position.

You must make the following settings to GRBL. This will set up the 0-10/pwm outputs to scale the BlackBox output voltage over the desired speed range.
set $30= max spindle speed 24000
set $31= min spindle speed 0

VFD parameters
PD01 = 1 this uses external terminals (FOR) to set run command.
PD02 = 1 this set the operating frequency to the external source (0-10)
PD011 = 0 Frequency lower limit. With external control the VFD will not allow the spindle to operate below this limit, this parameter is a safeguard to keep you from operating the spindle a speed that might damage it. If you want the 0-10 volt signal to be able to stop the spindle this needs to be set at 0 and you should be aware that you can operate the spindle at a speed that might damage it.
PD044 = 2 this default, FOR input to run spindle
PD070 = 0 Analog input 0=0-10v OR if you prefer pwm 1= 0-5v (PWM)

The following two parameters correlate to the GRBL $30 & $31 these set the VFD to accept the 0-10 or PWM range that the BLACKBOX will output and set the spindle speed accordingly.
PD072 = 400 High Analog Frequency. 400hz = 24000rpm
PD073 = 0 Low Analog Frequency.

USING CUSTOM FIRMWARE AND THE 'USE_SPINDLE_DIR_AS_ENABLE_PIN'
This option is more work than the other options for sure. However, this gives you speed control over the spindle and allows you to set a min speed protecting the spindle from possible operator or g-code mistakes. This may also open up other options for you, such as setting the output relay on the VFD to turn on and off with the run command.

Set all parameters from 'BASIC MOTOR SETTINGS'

Connect and set up everything from '0-10 OR PWM SPEED CONTROL' with the following 4 changes.

1. Connect the RELAY outputs COM and NO from the blackbox to the FOR and DCM on the VFD. Don't install the FOR-DCM jumper described in the section above.
   
   
2. Set GRBL $31 to your min spindle speed. I used 9000rpms.
   
   
3. Set PD011 = 150 this is your safeguard to not run the spindle below a min speed.
   
   
4. Set PD073 = 150 to you min speed. I used 150 for 9000rpms.

Set the onboard relay jumper in the blackbox to DIR/VFD
Basic steps I took to install custom grbl firmware

1. download and install the arduino IDE
2. download grbl source code
3. install grbl library in arduino ide
4. edit the grbl config.h that has been imported in your libraries to include the 'USE_SPINDLE_DIR_AS_ENABLE_PIN'option
5. compile the grblUpload
6. use the adruino IDE and a programmer to install the firmware on the black box

Compiling Grbl · gnea/grbl Wiki

You need to write the firmware to the black box with a programmer. If you don't to use a programmer the arduino bootloader on the black box will toggle the pin 13 at boot up. This will briefly toggle on your spindle upon connection of the blackbox. This is detailed in the GRBL code. You can find further information here. Question about custom firmware