That film cap ( white ) is what did the Kaboom. Resisters are to protect the gates of the switching transistors. I've had ring side seats to capacitors blowing up. It's bloody loud and dangerous. Lucky I didn't loose my eyesight the first time. Capacitors don't like being installed backwards! Sounds like a shotgun when they blow up. Enjoyed your adventures. Mark
G'day Mark, yes it was quite loud. I would have suspected the capacitor to but they are all intact. The film cap only had some soot that rubbed of easily. The resistor has a great chunk blown out the side of it and was still glowing red when I put the flame out. This caused the switching relay to catch fire and smoke everything out. Anyway I'm well into the new arrangement. I've taken the base out and drilled the 2 new mounting holes for the rear and put it back onto the Lathe. Next job is the Pulley and Brake Drum. Now this is where I really needed the big lathe. Cam
I hope you were wearing your brown pants when the drive blew! I'm keen to see you using the slotting head for the pulley keyway. I haven't used my slotter at all yet. I'm a bit scared of it, and the right project hasn't come along yet.
G'Day Mark, unfortunately the camera wasn't running at the time so you also didn't see me running around like a headless chook dealing with it. I haven't done a lot of slotting with this head (it is home made) so we will see how it goes. Cam
Ouch!, 240 single to 415V 3 phase inverters are not the best, 240 to 240V 3 phase are more reliable, I don't think any high end manufacturer makes the 240 step up 3 phase types. Looking forward to seeing it all back in operation. Thanks for sharing.
Sory to hear about your vfd going down. Would think it should of lasted longer than that. Things just don't seem to last anymore. Glad you've got it all sorted
G'Day John, yes they certainly don't last like they used to. The generated heat to convert from 240v single phase to 415v three phase must be enormous. Anyway I'm back to the drives I know and am confident with. Cam
Gday Cam, I bet there was a change of jocks then the drive went bang, not a cheap exercise but that’s what happens in this hobby mate, there’s always something, looking forward to the next video, cheers
G'Day Matty, yes these things are sent to try us. I'm going to be following in your footsteps with the machining of the Pulley and Brake Drum. Now this is where I really needed the big lathe. Anyway we work with what we have. Cam
That's a bummer Cam . I have 2 large braking resistors externally mounted on my VFD on the Bridgeport to take away excess current . Is there any reason you can not press in a keyed sleeve the same OD as the protruding boss on the brake side as it's not a high horsepower motor with sudden starts ? Cheers 👍
G'Day Max, Unfortunately with the NFlixin 415v 3 phase drive I can't fit breaking resistors from a single phase source. I can with the new 240v 3 Phase Folinn drive so will be doing that in the future on both lathes. I guess one issue with using the old pulley is that it is cast iron and I did damage the brake drum rim (which is very thin) trying to get it off. I hate dealing with cast iron in these situations where a large force is required to move it, cracking is a real possibility with such a brittle structure, wish they would use a spheroidal graphite iron for these machine elements.
G'day Chris, I was running the lathe for some time with the motor as a 4 pole. Just out of curiosity I changed it to the 8 pole configuration about a year ago to see if there was a differance but didn't really notice any change. Cam
G'day Dutchy, I had a very experienced Electrical Engineer look at it. Apart from what is obvious we don't know what other damage may have occurred. It was cheaper and less of a headache to go with what I know works. Cam
Hi Cam. Such is life. Whenever the magic smoke arrises you always wonder afterwards why it never happens when the camera is running ;) A Mini Hiroshima in the workshop is usually a quite spectacular event. I'm not sure why you swapped out the original motor though Cam if it was an inverter cooling issue? Cheers Rob
Hi Rob, yes it would have been nice to show the thing going up and me running around like a headless chock. The reason I had to change the motor out to suit the new drive, as with all these drives they will only run on 240V 3 phase. The motor needs to be reconfigured into Delta. This was a special as all motors from 5.5KW up are 415v/740v 3 phase. As I mentioned I was able to get this 5.5kw unit as a special in a configuration that can run 240v 3 phase. I wanted to get an 8 pole 5.5kw motor in a 132M frame in 240v 3 phase so I didn't need to modify the base but unfortunately these can't run with 240v 3 phase. Cam
Hi Cam - I'd followed the install of your original single phase 240v to three phase 415v VFD with some interest as I'm running through options for a similar setup on a three phase 415v mill at the moment - glad you'd got a few years of solid use out of the original one, before it overheated - looks like the Folinn unit is back to a 240v to 240v setup and hence the need for the new motor ? (looks like you're running delta and at the higher current to develop the desired power) - just curious whether you'd re-researched any more 240v to 415v units currently available and what had ultimately triggered the decision back to 240/240 and the new motor - I'm only at 2.2kW (and thankfully in a fairly cool workshop under the house !) so a 240/415 unit would still be of interest if I could find something suitable - any thoughts/observations welcome - thanks Rod
G'Day Rod, yep back to 3 Phase Delt at 240V 3 phase. All me other machines are running this way, I only have one machine running with the Huanyang unit as all the others have failed. The last machine is the Mill and it occasionally cuts out mid machining so I may be looking at replacing that soon. The Folinn unit is quite a bit more expensive but I'm more than happy with it on the Lathe and I have local support if needed. I haven't researched any other 415V 3 phase units but I'm sure we will see others coming onto the market. At this stage I'd probably wait until the design is a little more mature and the heat issue is re-solved. Cam
Hi Cam - Ok great, thanks very much for the feedback, confirmed my suspicion that the 240/415 units might be pushing the boundaries a bit - my mill is a CVT style variable speed, so I don't actually need the VFD for speed control, but was just contemplating a 240/415 unit as perhaps an "easier" way to get 3 phase 415 than setting up a phase change converter with a load motor etc - at the moment I'm just using a cheap Vevor 240/240 unit (which I had floating around for another project) wired Wye and not loading things up too much - we've actually got all 3 phases coming in from the street (main house, granny flat and old off-peak hot water system) but a very old metering setup - I'll probably just bite the bullet and get a proper 3 phase meter installed, but was keen to at least explore other options, hence my original question - think your 240/240 Folinn setup will be great (and reliable) and look forward to watching your next project(s) as they unfold - thanks again - cheers Rod
Hi Cam, looks like the braking resistors cooked, I'm very cautious on the decel rate setting on my drives, err on the conservative side. What about removing rotor and machining shaft to suit existing pulley, save a lot of machining?
G'day Willem, this unit cannot run with resistive braking from the single phase source. This is a question l continually asked the supplier and finally got an answer I could understand. The resisters are an add on with the Flixen unit but only with 3 phase in and 3 phase out. I can however mount them on the new 240v 3 phase inverters. Cam
That film cap ( white ) is what did the Kaboom. Resisters are to protect the gates of the switching transistors. I've had ring side seats to capacitors blowing up. It's bloody loud and dangerous. Lucky I didn't loose my eyesight the first time. Capacitors don't like being installed backwards! Sounds like a shotgun when they blow up.
Enjoyed your adventures.
Mark
G'day Mark, yes it was quite loud. I would have suspected the capacitor to but they are all intact. The film cap only had some soot that rubbed of easily. The resistor has a great chunk blown out the side of it and was still glowing red when I put the flame out. This caused the switching relay to catch fire and smoke everything out. Anyway I'm well into the new arrangement. I've taken the base out and drilled the 2 new mounting holes for the rear and put it back onto the Lathe. Next job is the Pulley and Brake Drum. Now this is where I really needed the big lathe.
Cam
I hope you were wearing your brown pants when the drive blew! I'm keen to see you using the slotting head for the pulley keyway. I haven't used my slotter at all yet. I'm a bit scared of it, and the right project hasn't come along yet.
G'Day Mark, unfortunately the camera wasn't running at the time so you also didn't see me running around like a headless chook dealing with it. I haven't done a lot of slotting with this head (it is home made) so we will see how it goes.
Cam
Ouch!, 240 single to 415V 3 phase inverters are not the best, 240 to 240V 3 phase are more reliable, I don't think any high end manufacturer makes the 240 step up 3 phase types.
Looking forward to seeing it all back in operation.
Thanks for sharing.
Sory to hear about your vfd going down. Would think it should of lasted longer than that. Things just don't seem to last anymore. Glad you've got it all sorted
G'Day John, yes they certainly don't last like they used to. The generated heat to convert from 240v single phase to 415v three phase must be enormous. Anyway I'm back to the drives I know and am confident with.
Cam
Gday Cam, I bet there was a change of jocks then the drive went bang, not a cheap exercise but that’s what happens in this hobby mate, there’s always something, looking forward to the next video, cheers
G'Day Matty, yes these things are sent to try us. I'm going to be following in your footsteps with the machining of the Pulley and Brake Drum. Now this is where I really needed the big lathe. Anyway we work with what we have.
Cam
That's a bummer Cam . I have 2 large braking resistors externally mounted on my VFD on the Bridgeport to take away excess current . Is there any reason you can not press in a keyed sleeve the same OD as the protruding boss on the brake side as it's not a high horsepower motor with sudden starts ? Cheers 👍
G'Day Max, Unfortunately with the NFlixin 415v 3 phase drive I can't fit breaking resistors from a single phase source. I can with the new 240v 3 Phase Folinn drive so will be doing that in the future on both lathes. I guess one issue with using the old pulley is that it is cast iron and I did damage the brake drum rim (which is very thin) trying to get it off. I hate dealing with cast iron in these situations where a large force is required to move it, cracking is a real possibility with such a brittle structure, wish they would use a spheroidal graphite iron for these machine elements.
A 5.5kW 8-pole motor provides half the speed and twice the torque of a 5.5kW 4-pole motor. Will your new setup provide enough torque ?
G'day Chris, I was running the lathe for some time with the motor as a 4 pole. Just out of curiosity I changed it to the 8 pole configuration about a year ago to see if there was a differance but didn't really notice any change.
Cam
Is there anything an electrician dould do to modify the circuit board of the busted VFD to make it better before using?
G'day Dutchy, I had a very experienced Electrical Engineer look at it. Apart from what is obvious we don't know what other damage may have occurred. It was cheaper and less of a headache to go with what I know works.
Cam
Hi Cam. Such is life. Whenever the magic smoke arrises you always wonder afterwards why it never happens when the camera is running ;) A Mini Hiroshima in the workshop is usually a quite spectacular event. I'm not sure why you swapped out the original motor though Cam if it was an inverter cooling issue? Cheers Rob
Hi Rob, yes it would have been nice to show the thing going up and me running around like a headless chock. The reason I had to change the motor out to suit the new drive, as with all these drives they will only run on 240V 3 phase. The motor needs to be reconfigured into Delta. This was a special as all motors from 5.5KW up are 415v/740v 3 phase. As I mentioned I was able to get this 5.5kw unit as a special in a configuration that can run 240v 3 phase. I wanted to get an 8 pole 5.5kw motor in a 132M frame in 240v 3 phase so I didn't need to modify the base but unfortunately these can't run with 240v 3 phase.
Cam
@@camatbattler2233 OK. I understand. I'm not up on this 3 phase trickery, thankfully ;) Cheers Rob
Hi Cam - I'd followed the install of your original single phase 240v to three phase 415v VFD with some interest as I'm running through options for a similar setup on a three phase 415v mill at the moment - glad you'd got a few years of solid use out of the original one, before it overheated - looks like the Folinn unit is back to a 240v to 240v setup and hence the need for the new motor ? (looks like you're running delta and at the higher current to develop the desired power) - just curious whether you'd re-researched any more 240v to 415v units currently available and what had ultimately triggered the decision back to 240/240 and the new motor - I'm only at 2.2kW (and thankfully in a fairly cool workshop under the house !) so a 240/415 unit would still be of interest if I could find something suitable - any thoughts/observations welcome - thanks Rod
I'll get back to Rodney, I did a very lengthy reply and then the Internet crapped out so lost everything.
Cam
Thanks
G'Day Rod, yep back to 3 Phase Delt at 240V 3 phase. All me other machines are running this way, I only have one machine running with the Huanyang unit as all the others have failed. The last machine is the Mill and it occasionally cuts out mid machining so I may be looking at replacing that soon. The Folinn unit is quite a bit more expensive but I'm more than happy with it on the Lathe and I have local support if needed. I haven't researched any other 415V 3 phase units but I'm sure we will see others coming onto the market. At this stage I'd probably wait until the design is a little more mature and the heat issue is re-solved.
Cam
Hi Cam - Ok great, thanks very much for the feedback, confirmed my suspicion that the 240/415 units might be pushing the boundaries a bit - my mill is a CVT style variable speed, so I don't actually need the VFD for speed control, but was just contemplating a 240/415 unit as perhaps an "easier" way to get 3 phase 415 than setting up a phase change converter with a load motor etc - at the moment I'm just using a cheap Vevor 240/240 unit (which I had floating around for another project) wired Wye and not loading things up too much - we've actually got all 3 phases coming in from the street (main house, granny flat and old off-peak hot water system) but a very old metering setup - I'll probably just bite the bullet and get a proper 3 phase meter installed, but was keen to at least explore other options, hence my original question - think your 240/240 Folinn setup will be great (and reliable) and look forward to watching your next project(s) as they unfold - thanks again - cheers Rod
What is the name of the new Electronics you are using I could not catch the name .
G'Day Chris, have a look at the photos on the end of the Video. Details are there but its a Folinn BD600 Series.
Cam
@@camatbattler2233 Hi Cam, where did you source this Folinn from?
Conon Motor in Bayswater Melbourne.
Cam
Hi Cam, looks like the braking resistors cooked, I'm very cautious on the decel rate setting on my drives, err on the conservative side.
What about removing rotor and machining shaft to suit existing pulley, save a lot of machining?
G'day Willem, this unit cannot run with resistive braking from the single phase source. This is a question l continually asked the supplier and finally got an answer I could understand. The resisters are an add on with the Flixen unit but only with 3 phase in and 3 phase out. I can however mount them on the new 240v 3 phase inverters.
Cam
36 dg will not cause that failure. Messing with the manufacturer’s electrical design will. Wear it you screwed up.