C3D VFD spindle and the "Cutter not responding" error

Hi there!

I’m a happy Shapeoko 3XXL owner that recently purchased a C3D spindle after wearing out a couple of the Dewalt trim routers - eventually the runout gets bad enough that it’s impossible to do clean work.

I’ve installed the VFD but randomly within 30 seconds of firing the spindle up via MDI the entire CNC disconnects, the spindle powers down and flashes “0.0”, and the “cutter not responding” error occurs.

Now I’ve had similar errors in the past that were due to static buildup especially when cutting plastics. So I have a hard line ground that connects the spindle clamp directly to one of the bolts on the outside of the controller enclosure. The wire runs with the rest of the cables back through the drag chains all of the way back to the controller. I get no resistance between the spindle body itself and the controller enclosure OR house ground.

Googling has shown that this is usually a static problem but I’m not sure what else to ground to what. And right now it’s disconnecting with nothing but the spindle running - it’s not moving or creating swarf to induce statis build up.

I have clamp on noise suppressors on my USB cable as well - that seemed to help in the past.

Is there something else I need to ground?

If your shop meets modern electric code you likely have a Ground Fault Interrupter Circuit (GCFI). Did you check that your GFCI did not pop. Some people never have the GCFI fail on their VFD spindles and others pop the GFCI every time they change speed. I have a Jet 1642 lathe with VFD and it cannot run on a GFCI circuit because it pops the GFCI so I have a single outlet in my shop that I run that lathe on. Check to see if your GCFI has popped.

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Good point, @gdon_2003. To add to this, the C3D documentation states: “VFD controller cannot run on a GFCI (ground fault ) outlet. If you have a GFCI outlet, the VFD will not function properly.”

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I’ll check for a GFCI inline, but if the GFCI tripped wouldn’t that simply cut the power? This isn’t a power cut - it’s a controller disconnect.

I’ll head down to the lab regardless to check it out! Thanks all - I really need to get to the bottom of this so I can make chips again!

No GCFI and I’m still getting disconnects. Sigh. No idea what the heck is going on here . . .

If your USB connection is loose, you will get the same message.

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I’ve switched the cable out a few times - let me see if I have another . . .

I like to arrange the cables where possible so that there is a coil putting tension onto the connection pushing the connector into the port.

I dealt with this for a couple years with my old 3xxl with a non carbide spindle.

If you have a laptop or a tablet try and run it without it plugged into wall power.

Mine would do the same if it was plugged in. Could never resolve it. Would even do it plugged into an inverter generator with the machine and the vfd into wall power.

Tried usb isolators. Emi filters, shielded cables, machine grounding, different vfd and spindle. Different control board, built a faraday cage around the vfd. Nothing worked.

I worked on this last night. I’ve tried grounding everything . . . no dice. I’ve replaced the USB cable and taped down the connector. It still constantly disconnects.

Should I call the C3D help line or something? I’m at wit’s end here . . .

Is there an error log somewhere that I can look through to see if the controller is reporting anything weird?

email support@carbide3d.com. 424-402-5203 (Support)

Only time I had to work on it is today - can someone please check my wiring to make sure that I’m not completely out of my mind? Which is likely at this point . . .

This is an original Shapeoko 3 XXL. I’ve added inductive proximity sensors, a Bitsetter, and a BitZero to the device. I just upgraded the controller to the 2.4g model to get the spindle sorted. Since grounding doesn’t seem to be helping I want to make sure that I’m not wired incorrectly.

Here are the labeled pics:

https://drive.google.com/file/d/1QZgUenwNbkgM4aCpjRn99mdfUTI0oRar/view?usp=sharing

https://drive.google.com/file/d/1Hj03BmO19a4b0o9s8jDddQ-i_MAtn6t5/view?usp=sharing