A small point , but when fitting wire into a hole rather larger than the wire, bend the wire back over to double it's thickness, this will give the screws more to bite on. Noel.
OK, thanks Noel.
The Estop needs to be Normally Open. I've searched the net but not found an answer – does it matter which wire goes into 3 and which into 4? One will connect to Com on the VFD, the other to port X6.
Wires can go either way around no difference in operation.
Pigtails cut short, and we removed the plasticy paint stuff for the earth contact, but looking at the outside connection I think the copper does still sit on a bit of paint so we'll remove more in case the paint is reducing contact with the metal surface. And either 3 or 4 for each of the wires is good to hear – I guess some things are so basic that nobody even mentions them on the net (I watched several youtube videos on how to fit Estops but didn't find the answer).
I just tried a dry run before attaching the enclosure to the wall, and it tripped the consumer unit. The circuit I tried it on is very sensitive, so I ran an extension cable from the circuit supplying rest of the house, and on which I initially tested the VFD and motor (and which worked fine), but it now trips the power protection plug. So it trips on both circuits.
The only thing that has changed physically is the earthing, and the location of the 3-phase motor on the lathe. Should I now connect the earths from the single and 3-phase cables direct to the vfd to check it still works as before, ie before I did the earthing to the enclosure? That would pinpoint the issue as the enclosure earthing. Or are there other things I can check first?
ps One other thing – we did away with the screened cable for the power input and the cable we used is 1.5mm2; I'm pretty sure the screened cable we tested with initially is bigger, the diameter measures about 2mm. Could that be an issue?
You don't say whether it is an RCD or MCB that is tripping ? Both can go out of spec and fail at lower trip currents. Was there a pre existing earth fault that now all is earthed up is showing ? 1.5mm cable is ample for the incoming. Power protection plug ? Disconnect JUST the vfd in the cabinet from the incoming and turn on – OK ? Check for loose strands short circuiting. You say the trip is very sensitive, normal RCD trip current is 30ma, has this regularly tripped and now failed ? Initial inrush current ? A simple wiring error, chech ALL connections. I take it you have no test gear ? You are working with MAINS voltage please be careful. Noel
Thank you Noel – most of that went over my head but I understand the concern about somebody who clearly doesn't know what he's doing (me) trying to deal with a mains electricity problem! I'm pretty cautious by nature and recognise my ignorance, hence my endless questions
The one thing that I wasn't confident about was the plug wiring – when I did the screened cable, it all sat in nicely; the rubber encased cable we switched to was strangely more difficult to get to sit properly. I couldn't see any loose cables/ threads, but decided to rewire the plug – hey presto, it's now working perfectly, and the lathe is running beautifully!
In the meantime, I checked all the connections are secure, as per yours Noel.
I now need to set the parameters and we'll be ready to attach the enclosure to the wall.
Apart from the Estop, I'm going to set undervoltage to 180, overvoltage to 260, and reduce Main current overload to 2500 mA (following advice on a Myford forum) unless anyone here can suggest those aren't good settings?