800W Water-Cooled Spindle Running on 110V

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zorlack
Posts: 20
Joined: Thu Feb 13, 2014 3:52 am

800W Water-Cooled Spindle Running on 110V

Post by zorlack » Sun Feb 23, 2014 6:27 pm

On Friday I received my Chinese water-cooled 800W 65mm spindle which I bought on ebay.

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Here's the business end, as I test fit it into my 3D-printed mount.

To power the spindle I'm using a Hitachi L100 running on a 110V wall outlet. Getting the L100 configured correctly was a pain. The spindle didn't come with any directions, so I spent about two hours trying to figure out if I had a software problem, or a wiring problem. In the end I had both.

In the end I had to set the Max Allowed Frequency to 360, and the Native Motor Frequency to 360 before the VFD would send the right signal. Once it did the spindle turned backwards. So it was a matter of reversing the wires. One thing to note is that this spindle does not seem to be wired for ground.

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Here's the final hookup.


And the runup!

The next problem to tackle was the water cooling. For cooling I used a $60 air conditioner condensate pump. The nice thing about this choice is that condensate pumps are readily available at home improvement stores, and its a combination pump and reservoir. Mine even has a sensor that could be used to detect "low coolant." In addition, the condensate pump moves water at about 1 gallon per minute, which is fast enough, but not so fast that it would stress the plumbing connections.

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Water hoses installed!

The condensate pump feeds water to the spindle, which flows out of the spindle into a salvaged PC cooling radiator. From the radiator water flows back into the body of the condensate pump.

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PC Radiator: Note the sketchy barb connections.

The PC Radiator has a 12V fan which needed to be powered. I spliced the connections to a PC molex connector and attached it to an external hard-drive power supply. (The +12v goes to the fan, and the +5v goes to the laser.)

The whole system holds about a half gallon of distilled water. I'm debating whether or not to add a cap full of bleach to prevent mold growth. Before installing the cooling the spindle would get warm to the touch after a minute or so of use. Now I can't detect any noticeable warmth. The whole system is connected to my e-stop circuit, so the pump is on whenever the VFD is energized.

Lastly I set up a little turret and did some carving to test everything out!

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"Boo", Carved in Corian Scrap

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A test in 6061 aluminum!

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My little setup!

jacob32123
Posts: 96
Joined: Thu Dec 12, 2013 4:53 am

Re: 800W Water-Cooled Spindle Running on 110V

Post by jacob32123 » Sun Feb 23, 2014 7:37 pm

Wow! Really nice setup! I'm looking at the same spindles for my machine. Where did you get yours?

EDIT: that VFD looks like it is 110v in, 220v out. Is that right?

zorlack
Posts: 20
Joined: Thu Feb 13, 2014 3:52 am

Re: 800W Water-Cooled Spindle Running on 110V

Post by zorlack » Sun Feb 23, 2014 8:59 pm

I ended up buying this one: http://www.ebay.com/itm/800W-CNC-Router ... 19e7515130

Total cost was about $200 after shipping.

The VFD is a Hitachi L100. It comes in a variety of different models, but the one I have takes in 110V and outputs 220V 3Phase. Mine is a L100-007MFU2, which means that it is 110V and rated at 750W (close enough to 800W).

Brian
Posts: 78
Joined: Sat Jan 25, 2014 8:42 pm
Location: Saint Louis

Re: 800W Water-Cooled Spindle Running on 110V

Post by Brian » Sun Feb 23, 2014 11:53 pm

What were your speeds, feeds and DOC for the 6061?

Spindle looks nice, tempted to grab one myself.
Brian
Shapeoko 2 #I have no idea
HF cutout tool, 72oz nema 17 steppers, TB6600 stepper drivers, Mach3 control

zorlack
Posts: 20
Joined: Thu Feb 13, 2014 3:52 am

Re: 800W Water-Cooled Spindle Running on 110V

Post by zorlack » Mon Feb 24, 2014 1:25 am

I used the following settings, which I cribbed from this post: http://www.shapeoko.com/forum/viewtopic.php?f=6&t=1912

Bit: .125" two-flute end-mill
Depth: 0.2mm per pass
Spindle: 10,000 RPM
Feed Rate: 500

Lots of WD-40... Cutting aluminum is kind of messy. It's a really awesome capability, but I can see why its not terribly popular.

Brian
Posts: 78
Joined: Sat Jan 25, 2014 8:42 pm
Location: Saint Louis

Re: 800W Water-Cooled Spindle Running on 110V

Post by Brian » Tue Feb 25, 2014 10:30 pm

zorlack wrote:I used the following settings, which I cribbed from this post: http://www.shapeoko.com/forum/viewtopic.php?f=6&t=1912

Bit: .125" two-flute end-mill
Depth: 0.2mm per pass
Spindle: 10,000 RPM
Feed Rate: 500

Lots of WD-40... Cutting aluminum is kind of messy. It's a really awesome capability, but I can see why its not terribly popular.
http://littlemachineshop.com/products/p ... uctID=2226

If you want to keep cutting alum you might look into something like this.
Brian
Shapeoko 2 #I have no idea
HF cutout tool, 72oz nema 17 steppers, TB6600 stepper drivers, Mach3 control

zorlack
Posts: 20
Joined: Thu Feb 13, 2014 3:52 am

Re: 800W Water-Cooled Spindle Running on 110V

Post by zorlack » Wed Feb 26, 2014 4:52 am

Definitely worth looking in to. I want to try setting up a compressed-air line for chip-clearing. I might be able to get away with light-duty aluminum work without having to coat my shop (aka basement) in cutting fluid. Hehe.

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