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01-09-2021 #21
I have done all of this johnny ( Just had motor apart a second time to re-bed brushes again this time with 320 grade paper and now running in again)
Makers tech rep suggested that I run the motor with a current limit of half capacity (set about 2 amps ) and use the belts to gear down. I tried this now normal running is at about 0.8 amps, 100 volts max at 9.7v dc input, but it still stalled on screwcutting. No signs of any motor problems , no arcing at the com , . Motor runs sweet just no torque boost when needed.
And as I have said before it was fine initially and handled all the loads I was going to put on it . Frustrating!
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01-09-2021 #22
That is frustrating. The motor should be able to draw up to 7 amps if its the original DC motor. The original lenze 534 controller was set at 8 amps max. Are you using the Lenze driver module.... if not whatever you replaced it with may have a problem with the ramping circuit something like a feedback resistor or amp has reduced gain due to damage from earlier brush problem. It responds but slow in outputting extra amps under load.
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02-09-2021 #23
I ran the motor today on a separate 42v power supply and of course it would only run at about 500 revs but at that I could take a millimeter off diameter in a single cut without stalling. So the motor seems to have the guts for the job.. Speed drops a tad and current goes up but the torque is there despite low voltage.
I reckon the drive has fallen over . Now waiting to hear what suppliers will do about it .
Drive is supposed to be self protecting so should look after itself if a brush wears out (you would think anyway)
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04-09-2021 #24
So Drive unit is heading back to the makers for testing.
Watch this space!
I expect they will find a problem with it . Just hope they accept it as warranty problem. I am confident I did nothing wrong
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18-09-2021 #25
So they said no fault , but they did me a deal on a 12,2 amp upgrade . (???)
Still no improvement and motor would only draw about 1.5 amps max settling down to 1.2 . I have concluded that brushes may be limiting the current input . No arcing , but brushes did not seem to be giving a "witness" over their full face width.
The brush width spans 3 comm segments so maybe only 1 in 3 being fully supplied .
Motor stripped again, segments cleaned and brushes bedded in another lathe using a jig. Then re-assembled taking care to keep the same brush orientation.
Seems better already although back to running in again, so will keep you posted .Last edited by John11668; 18-09-2021 at 07:21 PM.
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20-09-2021 #26
Hey John. Are you still using the LENZE 534 driver module? I'm not sure if motor can handle 12.2 Amps as Boxford set max to 8 Amps ,,,but learning learning. My LENZE 534 has stopped working and I am trying to trace fault. I had to replace capacitor across the mains input but it still does not function. I am trying to work out how the Simplatron DCVT-2 interface board controls the input of the LENZE driver. I have traced fault to output of DCVT-2 board. I just need to know if the DCVT-2 generates the 10v reference from A (white wire) on DCVT-2 connected to Pin 9 labelled +VCC in Useless LENZE manual. Can you disconnect white wire and report if 3 to 10 volts dc is present between A and C terminals on DCVT-2 board or that 10 volts is generated on pins 7 and 9 on LENZE board---with white wire disconnected. That would help a lot thanks.
I have checked that 180 volts is present and the IXYS Half Controlled Single phase Rectifier Bridge is fine and waiting for dual Gate control to start motor.
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20-09-2021 #27
Sorry Johnny but my Lenze unit died so I cant test anything for you.
My Sprint 340i was not even giving its full 3.4 amps unless I stalled the spindle, but Sprint felt that 680i might be under-rated hence recommending 1220i.
It is however governed down to an I max of about 50% or 6 amps .
Having said that, since I rebuilt the motor torque is much better but I have not seen the motor draw more than 1.5A.
But as I said on another thread there are a couple of GEC gemini dc controllers on Ebay at the moment .
Looks like Boxford used these as an alternative to Lenze
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21-09-2021 #28
Thanks John
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