Next Wave CNC SHARK - User Manual

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Installation Manual16 pages

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Summary

Shark CNC Spindle VFD Setup Guide

Parts List from Next Wave

Lists components provided by Next Wave for the spindle VFD setup.

Customer- Supplied Parts and Tools

Details required tools and parts to be provided by the user for setup.

VFD Initial Preparation Steps

Unplugging the VFD power supply and removing the front cover.

Jumper Setting for VI Position

Moving the internal jumper to the VI (left) position for speed control.

Terminal Block Configuration

Loosening specific terminals (DCM, ACM, RS-, RS+) for wiring.

Speed Control Cable Routing

Guiding the speed control cable through the VFD's bottom grommet.

Wiring Connections to Terminals

Connecting jumper wire, green, black, and red wires to designated terminals.

Securing the Spindle Cable

Using a zip tie to bundle the spindle cable and trimming excess.

Reattaching VFD Front Panel

Securing the VFD's front panel after internal wiring is completed.

Connecting VFD to Power Outlet

Plugging the VFD power cord into a 110V outlet and observing the display.

Navigating VFD Program Settings

Accessing program parameters (e.g., Pdxxx) using the PRGM button.

Configuring Spindle Speed Parameter (Pd001)

Setting the program registry number to Pd001 and accessing its configuration window.

Setting Parameter Value and Saving Changes

Adjusting the setting for Pd001 to '2' and saving the configuration.

Bulk Parameter Configuration

Repeating the setup process for other listed registry numbers and using programming tips.

Connecting VFD to Control Box

Unplugging the VFD and connecting the interface cable to the control box port.

Firmware, Post-processor, and Power-Up Sequence

Updating software, setting RPM, and performing the correct power-on sequence for synchronization.

Troubleshooting and Technical Support

Guidance for VFD/Control Box sync issues and contact information for assistance.

This document outlines the setup procedure for the Shark CNC Spindle VFD (inverter) to enable the use of a Spindle Speed Interface cable, allowing for automated spindle speed control. The process involves both hardware modifications to the VFD and software updates for the CNC control box and post-processor.

Function Description:

The Shark CNC Spindle VFD (Variable Frequency Drive), also known as an inverter, is a crucial component that controls the speed of the CNC spindle motor. By integrating the Spindle Speed Interface cable, the VFD can receive speed commands directly from the CNC control box, enabling automated RPM adjustments based on the toolpath settings defined in CAM software like VCarve or Aspire. This eliminates the need for manual speed adjustments on the VFD, streamlining the machining process and improving precision. The system is designed to ensure that RPM settings from the CAM software are accurately translated to the spindle, enhancing the overall efficiency and reliability of the CNC operation.

Important Technical Specifications:

The VFD operates on a 110V power supply and is rated for 1.5KW, as indicated by the "110V 1.5KW" label on the unit. The setup requires specific electrical connections within the VFD's terminal block, including DCM, ACM, RS-, and RS+ terminals, which are used for the speed control interface. A jumper wire (1 to 1.5" long, braided or solid 18 or 20-gauge) is needed to connect DCM and ACM. The Spindle Speed Interface cable itself connects to the VFD and then to the control box, transmitting the necessary signals for speed control.

The system relies on specific firmware and software versions for proper functionality:

Controller Firmware: Version v4.5.x.x or higher is required for the CNC control box.
VCarve/Aspire Post Processor: An updated post-processor is necessary to ensure that RPM settings are correctly embedded in the .tap files generated by the CAM software.

The VFD's display shows various parameters, including "Pdxxx" for program registry numbers and "Hz," "RPM," and other views for operational status. The setup involves modifying several program registry settings (e.g., PD001, PD002, PD004, PD005, PD008, PD009, PD010, PD011, PD014, PD015, PD070, PD072, PD141, PD142, PD143, PD144, PD163, PD164, PD165) to configure the VFD for external speed control.

Usage Features:

Once set up, the system offers several key usage features:

Automated Spindle Speed Control: RPM settings defined in VCarve/Aspire are automatically applied by the spindle when a .tap file is run. This eliminates manual intervention and ensures consistent machining parameters.
Simplified Operation: The user no longer needs to manually adjust the VFD's speed dial or buttons during operation, as the CNC control box manages this automatically.
Integrated Workflow: The updated post-processor ensures a seamless workflow from CAM software to machine operation, with speed settings directly incorporated into the G-code.
Visual Feedback: The VFD's display provides visual feedback on the current RPM speed when in the normal/default view (after a tap file is run), allowing the user to confirm the operational speed.

Maintenance Features:

The setup and ongoing maintenance involve several steps to ensure proper functionality:

Firmware and Software Updates: Regular updates to the control box firmware and VCarve/Aspire post-processor are essential to maintain compatibility and access new features or bug fixes. Links are provided in the manual for these updates.
Cable Management: The use of zip ties to secure the Spindle cable to other cables helps in organizing the wiring and preventing accidental disconnections or damage.
Power Sequencing: A critical maintenance feature is the correct power-up sequence. The VFD MUST be turned ON and fully active before turning on the Control Box. This allows the VFD and Control Box to correctly sync, preventing issues with automatic spindle startup. Plugging both units into a switched power strip simplifies this process.
Terminal Connections: Ensuring that all terminal connections (DCM, ACM, RS-, RS+) are tightened and that wires cannot be pulled out is crucial for reliable operation and to prevent intermittent issues.
Jumper Position: Verifying that the jumper within the VFD is correctly set to the "VI (left)" position is a one-time setup step but should be checked if issues arise.
Program Registry Settings: While the manual provides specific settings for the program registry, it explicitly warns against changing any other settings to prevent damage to the spindle. This highlights the importance of adhering strictly to the provided configuration.
Troubleshooting Support: In case of problems, technical support is available via email, providing a clear channel for assistance with setup or operational issues.