Fanuc 2S AC spindle motor on Delta C2000+

Hi All,

I have finally reached the point in my Kitamura CNC retrofit that i can get the spindle turning.
I got a Delta 3.7KW C2000+ (3PH 380v) VFD + PG-01H encoder card. But I'm having some interesting issues....

So My Spindle motor is an old FANUC 2S 2.2 / 3.7KW 200V 4P 1500/8000rpm spindle motor:

Datasheet link:  s3.amazonaws.com/Icarus/DOCUMENTS/Fanuc_Manuals_1791.pdf So what I tried is to first figure out if this is an AC induction motor or an PM motor. From what I can find (or not find in this case) anything in the datasheet so that made me think it is an AC motor as i feel no "dents" when i turn the motor by hand.
So I connected it all including the OEM Fanuc encoder signals the the VFD.
And then I went through the setup wizard, (immediately went for the complicated method) of including the encoder feedback etc.
When i tried to do a test run it just immediately jumps in OL3 error. I tried some of the advisement in the datasheet such as changing accel time or carrier frequency but that did not help.

So i went back to the basics and just put it in V/F mode. Max output voltage 200V , poles: 4 , max freq 267Hz , base freq 50hz (1500rpm) .
Now when i pressed run it turned, but it did not sound good. The current was around 17A's when it runs with no load on like 500rpm. I tried to set it to higher RPM but the high load pretty much states around. After a bit the VFD throws and overload as it is pulling too much current.

And now... I'm quite lost, any idea what I'm doing wrong? I have worked quite a bit with vfd's and never had such troubles so I'm thinking there is something fundamentally wrong. (this servo spindle worked well with the FANUC drive it had before).

That Fanuc is an induction motor, not a PM.  They will run off a bog-standard VFD; the problem with Fanuc spindle motors is that they generally use a serial or proprietary encoder output that doesn't play well with 'standard' encoder inputs on drives.

First - disconnect your encoder from the VFD, and set the VFD to no-feedback.

The VFD 'wizard' should have an option to enter the basic nameplate data (FL amps, poles, ect.).  Try using that in V/F mode.

I've got a Mitsubishi SJ (similar to your Fanuc) I'm running off a GS3 VFD.

EDIT - Tommy's right.  Your voltage is wrong.  That's a 200v-class motor, can't use it with a 380v VFD unless the VFD can be programmed to drop the voltage to a different class.

EDIT 2 - DOH! See later post

trying VF control with lower voltage base , ex 150v
fanuc spindle use SIN COS encoder, it is not incr ABZ encoder

regards

The VFD is programmed to output 200V max. It is indeed a SIN-COS encoder and that works with the PG01-H encoder card that i use.
But when running in v/f mode this is not used anyway.

"The VFD 'wizard' should have an option to enter the basic nameplate data (FL amps, poles, ect.).  Try using that in V/F mode."
I did this, it just runs very rough, not how it used to run before at all.

My VFD can run all kind of setups including PM ones. One thing that makes me think it is PM after all is that the torque curve is basically max torque from 0rpm and goes down from there + It runs like shit in V/F mode as an induction motor.

I'm kinda tempted to just throw in in PM mode and see if it changes. Cause this does not seem to be it at all.

In a video on yt regarding a brother update they also set it to PM mode. The motor looks to be the same frame style as mine:

Reset the vfd, did startup wizard, only changed these parameters (bold = default):
P00-10 control method velocity mode
P00-11 velocity mode vf open ctrl
P00-16 load select heavy duty
P00-17 carrier freq 4khz
P1-00 max out freq 250hz
P1-01 motor f base 50hz
P1-02 max out volt 1 200v
P1-10 mid out freq 1-1 3hz
P1-04 mid out volt 1-1 22v
p1-05 mid out freq 1-2 1.5hz
p1-06 mid out volt 1-2 10v
P1-07 mid-put- freq 1 1.5hz
​​​p1-08 min out-volt 1 32v
P1-10 upper bound freq 250hz
p1-12 1st accel time 10s

vid: youtube.com/shorts/VwO0N8tdShA?si=rAUIbYFLjQx5ai4V

I'm kinda thinking this vfd is just too underrrated for this setup.
Considering the output voltage is max 200V and my vfd is limited to ~11A , it could handle the ~2.2kw max of the motor. but probably has too little juice for low rpm's.

As when it is trying to ramp up the current on the display is like 17.5A which my vfd can do in short burst but not long.

That would leave the following options:
- Fit it with a 7.5 -10kw vfd
- Re-fit the OEM 380 - 200V trafo and get a 3X230v ~4kw vfd
- Replace the motor with a china 380V equivalent

I'm thinking about the last option as that makes life easier. The cost of all of these options are pretty much the same.

Yes, usually for lower voltage you need a more powerful driver.  But it should still work but you won't be able to use it at full power.  Did you follow these settings?

 

Let me go run auto-tune. And see if it changes much.