Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-15 Thread Marcus Bowman

On 15 May 2015, at 10:03, andy pugh wrote:

 On 15 May 2015 at 02:02, Tom Easterday tom-...@bgp.nu wrote:
 I don’t have extra wire to do them individually and my wire is a 
 multi-conductor (3 + ground).  So I am going to put 4 ferrites together over 
 the whole cable (including ground)
 
 You can just take the same 4-core wire 3x through the same ferrite.
 

Ferrite chokes are interesting things, but its not a case of more turns is 
better, or any-ferrite-will-do.
I was at a talk about making ferrite chokes on Wednesday evening, and You might 
find some techniques of interest at the speaker's site, here:

http://www.ifwtech.co.uk/g3sek/

Look for the In Practice section towards the bottom of the page.
The results from a properly tuned ferrite choke are impressive.


Marcus


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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-15 Thread andy pugh
On 15 May 2015 at 02:02, Tom Easterday tom-...@bgp.nu wrote:
 I don’t have extra wire to do them individually and my wire is a 
 multi-conductor (3 + ground).  So I am going to put 4 ferrites together over 
 the whole cable (including ground)

You can just take the same 4-core wire 3x through the same ferrite.

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-15 Thread Gene Heskett
On Friday 15 May 2015 05:43:14 Marcus Bowman wrote:
 On 15 May 2015, at 10:03, andy pugh wrote:
  On 15 May 2015 at 02:02, Tom Easterday tom-...@bgp.nu wrote:
  I don’t have extra wire to do them individually and my wire is a
  multi-conductor (3 + ground).  So I am going to put 4 ferrites
  together over the whole cable (including ground)
 
  You can just take the same 4-core wire 3x through the same ferrite.

 Ferrite chokes are interesting things, but its not a case of more
 turns is better, or any-ferrite-will-do. I was at a talk about making
 ferrite chokes on Wednesday evening, and You might find some
 techniques of interest at the speaker's site, here:

 http://www.ifwtech.co.uk/g3sek/

 Look for the In Practice section towards the bottom of the page.
 The results from a properly tuned ferrite choke are impressive.

So are the results of taking a ferrite above its curie temperature while 
under power.  And many of those very impressive ferrites have a curie 
temp well below boiling water...

 Marcus

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-14 Thread Tom Easterday
I spent some time with the spectrum analyzer but did’t have much luck in 
isolating the sink for the noise.  I just verified that my VFD does indeed 
produce a large amount of noise between low kHz and about 10MHz!  I did some 
re-routing of wires and replaced some that weren’t shielded.  I ordered some 
ferrites for the VFD-motor wiring and my computer I/O extension cabling which 
will be here in a couple days.

However, I did find the source of the main problem!  It was indeed my keyboard. 
 Not the USB wiring from keyboard to pc, but the keyboard ITSELF is very 
sensitive to the noise created by the VFD.  If I move the keyboard to the very 
extreme end of it’s (rather long) usb cable the problem disappears completely. 
6” closer to the cabinet and noise reappears.  Apparently the noise is being 
interpreted as key presses by the keyboard circuitry.  I replaced the new water 
resistant Logitech keyboard with a very old Apple keyboard I had lying around 
and no more random characters!   I also had a second problem where the VFD 
would shut down somewhat randomly which I thought was related to this noise as 
well.  That turned out to be an over current condition at very low rpm.  
Tweaking some settings fixed that.

The Rasmi input filter, and various re-wiring and shielding I did was probably 
not needed, but in the long run perhaps it will save me from other problems.

Thanks, for all the input,
-Tom


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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-14 Thread Dave Cole
 The Rasmi input filter

Take it off and see what happens

If that drive is screwing with your keyboard that is on the OUTSIDE of your 
control cabinet, imagine what kind of RF exposure is on the inside of your 
control cabinet!

Those AD VFDs should also be sold as EMI test generators.  ;-)

Dave



On 5/14/2015 8:53 AM, Tom Easterday wrote:
 I spent some time with the spectrum analyzer but did’t have much luck in 
 isolating the sink for the noise.  I just verified that my VFD does indeed 
 produce a large amount of noise between low kHz and about 10MHz!  I did some 
 re-routing of wires and replaced some that weren’t shielded.  I ordered some 
 ferrites for the VFD-motor wiring and my computer I/O extension cabling which 
 will be here in a couple days.

 However, I did find the source of the main problem!  It was indeed my 
 keyboard.  Not the USB wiring from keyboard to pc, but the keyboard ITSELF is 
 very sensitive to the noise created by the VFD.  If I move the keyboard to 
 the very extreme end of it’s (rather long) usb cable the problem disappears 
 completely. 6” closer to the cabinet and noise reappears.  Apparently the 
 noise is being interpreted as key presses by the keyboard circuitry.  I 
 replaced the new water resistant Logitech keyboard with a very old Apple 
 keyboard I had lying around and no more random characters!   I also had a 
 second problem where the VFD would shut down somewhat randomly which I 
 thought was related to this noise as well.  That turned out to be an over 
 current condition at very low rpm.  Tweaking some settings fixed that.

 The Rasmi input filter, and various re-wiring and shielding I did was 
 probably not needed, but in the long run perhaps it will save me from other 
 problems.

 Thanks, for all the input,
 -Tom


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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-14 Thread Rick Lair
I have been following this thread somewhat, and have a question,

What is the difference between a line reactor and emi input filter?

We have a AD GS3 40hp drive in our turning center, and have the same 
noise problems with the drive, and I am not sure which one to buy, or do 
I need both? The drive schematic shows putting an emi filter on both 
sides of the drive, would that help as well? At $272 bucks a piece, I 
don't want to throw money away, but I do want to get this put to bed, we 
have been dealing with it for 2 years now, and I am getting tired of it.

Thanks

Rick

On 5/14/2015 9:53 AM, Dave Cole wrote:
 The Rasmi input filter
 Take it off and see what happens

 If that drive is screwing with your keyboard that is on the OUTSIDE of your 
 control cabinet, imagine what kind of RF exposure is on the inside of your 
 control cabinet!

 Those AD VFDs should also be sold as EMI test generators.  ;-)

 Dave



 On 5/14/2015 8:53 AM, Tom Easterday wrote:
 I spent some time with the spectrum analyzer but did’t have much luck in 
 isolating the sink for the noise.  I just verified that my VFD does indeed 
 produce a large amount of noise between low kHz and about 10MHz!  I did some 
 re-routing of wires and replaced some that weren’t shielded.  I ordered some 
 ferrites for the VFD-motor wiring and my computer I/O extension cabling 
 which will be here in a couple days.

 However, I did find the source of the main problem!  It was indeed my 
 keyboard.  Not the USB wiring from keyboard to pc, but the keyboard ITSELF 
 is very sensitive to the noise created by the VFD.  If I move the keyboard 
 to the very extreme end of it’s (rather long) usb cable the problem 
 disappears completely. 6” closer to the cabinet and noise reappears.  
 Apparently the noise is being interpreted as key presses by the keyboard 
 circuitry.  I replaced the new water resistant Logitech keyboard with a very 
 old Apple keyboard I had lying around and no more random characters!   I 
 also had a second problem where the VFD would shut down somewhat randomly 
 which I thought was related to this noise as well.  That turned out to be an 
 over current condition at very low rpm.  Tweaking some settings fixed that.

 The Rasmi input filter, and various re-wiring and shielding I did was 
 probably not needed, but in the long run perhaps it will save me from other 
 problems.

 Thanks, for all the input,
 -Tom


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Thanks


Rick Lair
Superior Roll  Turning LLC
399 East Center Street
Petersburg MI, 49270
PH: 734-279-1831
FAX: 734-279-1166
www.superiorroll.com


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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-14 Thread Jon Elson
On 05/14/2015 07:53 AM, Tom Easterday wrote:
I also had a second problem where the VFD would shut down somewhat 
 randomly which I thought was related to this noise as well.  That turned out 
 to be an over current condition at very low rpm.  Tweaking some settings 
 fixed that.


Yes, I had to turn off the electronic motor protection on my 
mill VFD, as it integrated an overtemp condition when doing 
rigid tapping.  All those reverses added up.  Since the 
Bridgeport motors are made for plug reversing when manual 
tapping all day long, I figure it can probably handle worse 
than the VFD could ever deliver.

Jon

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-14 Thread Jon Elson
On 05/14/2015 09:38 AM, Rick Lair wrote:
 I have been following this thread somewhat, and have a question,

 What is the difference between a line reactor and emi input filter?
A line reactor may be designed to reduce the 3rd harmonic 
produced by typical rectifier/capacitor 3-phase loads, and 
not worry much about higher harmonics.  An EMI filter may 
not do anything for 3rd harmonic, but will be optimized to 
suppress conducted emissions on anything above a few hudred KHz.
 We have a AD GS3 40hp drive in our turning center, and have the same
 noise problems with the drive, and I am not sure which one to buy, or do
 I need both? The drive schematic shows putting an emi filter on both
 sides of the drive, would that help as well?
Yes, the output side of the VFD is radiating at least as 
much, if not more, EMI than the input.
   At $272 bucks a piece, I
 don't want to throw money away, but I do want to get this put to bed, we
 have been dealing with it for 2 years now, and I am getting tired of it.


You may not need a $272 unit, although for 130 A line 
current (assuming 240 V, half that for 480 V)
they will be a bit expensive.  There are shielded cables for 
VFD to motor connections that are supposed to help.

Exactly what is being affected by the EMI?  The control 
itself, or other gear in the plant?  If the control of that 
machine is being affected, then it could be either, or 
both.  if other plant equipment, then if the VFD is in a 
cabinet directly on the machine, then it sounds mostly like 
it is coupling through the input to the VFD, so I'd put the 
money at the input side first.  Also, make sure the machine 
frame is securely grounded to the electrical panel ground.  
EMI return currents will flow through the ground.  if the 
machine has a plugged-in power cord (Hubbel twist-lock 
style) then maybe run an additional ground to the outlet 
box.  (Hmmm, 40 Hp machines won't likely be plugged in, even 
at 480.)

You can get into trouble putting EMI filters on the output 
of the VFD, as this can cause excessive currents that can 
damage either the filter or the VFD.  So, for the output 
side, use ONLY a filter recommended by the VFD maker.
On the input side, you can use any filter that can handle 
the current draw, so you are not restricted by the VFD 
maker's recommendations.

Jon

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-14 Thread Karlsson Wang
I guess a common mode filter will be good but I have almost only theoretical 
knowledge and very limited experience.

Nicklas Karlsson



On Thu, 14 May 2015 10:38:43 -0400
Rick Lair r...@superiorroll.com wrote:

 I have been following this thread somewhat, and have a question,
 
 What is the difference between a line reactor and emi input filter?
 
 We have a AD GS3 40hp drive in our turning center, and have the same 
 noise problems with the drive, and I am not sure which one to buy, or do 
 I need both? The drive schematic shows putting an emi filter on both 
 sides of the drive, would that help as well? At $272 bucks a piece, I 
 don't want to throw money away, but I do want to get this put to bed, we 
 have been dealing with it for 2 years now, and I am getting tired of it.
 
 Thanks
 
 Rick
 
 On 5/14/2015 9:53 AM, Dave Cole wrote:
  The Rasmi input filter
  Take it off and see what happens
 
  If that drive is screwing with your keyboard that is on the OUTSIDE of your 
  control cabinet, imagine what kind of RF exposure is on the inside of your 
  control cabinet!
 
  Those AD VFDs should also be sold as EMI test generators.  ;-)
 
  Dave
 
 
 
  On 5/14/2015 8:53 AM, Tom Easterday wrote:
  I spent some time with the spectrum analyzer but did’t have much luck in 
  isolating the sink for the noise.  I just verified that my VFD does indeed 
  produce a large amount of noise between low kHz and about 10MHz!  I did 
  some re-routing of wires and replaced some that weren’t shielded.  I 
  ordered some ferrites for the VFD-motor wiring and my computer I/O 
  extension cabling which will be here in a couple days.
 
  However, I did find the source of the main problem!  It was indeed my 
  keyboard.  Not the USB wiring from keyboard to pc, but the keyboard ITSELF 
  is very sensitive to the noise created by the VFD.  If I move the keyboard 
  to the very extreme end of it’s (rather long) usb cable the problem 
  disappears completely. 6” closer to the cabinet and noise reappears.  
  Apparently the noise is being interpreted as key presses by the keyboard 
  circuitry.  I replaced the new water resistant Logitech keyboard with a 
  very old Apple keyboard I had lying around and no more random characters!  
   I also had a second problem where the VFD would shut down somewhat 
  randomly which I thought was related to this noise as well.  That turned 
  out to be an over current condition at very low rpm.  Tweaking some 
  settings fixed that.
 
  The Rasmi input filter, and various re-wiring and shielding I did was 
  probably not needed, but in the long run perhaps it will save me from 
  other problems.
 
  Thanks, for all the input,
  -Tom
 
 
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 Thanks
 
 
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 Superior Roll  Turning LLC
 399 East Center Street
 Petersburg MI, 49270
 PH: 734-279-1831
 FAX: 734-279-1166
 www.superiorroll.com
 
 
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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-14 Thread Peter C. Wallace

On Thu, 14 May 2015, Karlsson  Wang wrote:


Date: Thu, 14 May 2015 21:53:05 +0200
From: Karlsson  Wang nicklas.karls...@karlssonwang.se
Reply-To: Enhanced Machine Controller (EMC)
emc-users@lists.sourceforge.net
To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
Subject: Re: [Emc-users] If there's one thing I hate, all the noise, noise,
noise, noise

I guess a common mode filter will be good but I have almost only theoretical 
knowledge and very limited experience.


Nicklas Karlsson


We found that common mode filters (big ferrite bead around U,V,W) on the motor 
leads help a lot. Otherwise you have ~360V square waves driving the stray 
wiring and motor capacitance and _nothing_ to limit the peak current of these 
fast edges driving into this capacitance to ground. This causes huge ground 
bumping of the VFD ground. A common mode choke limits these peak currents 
considerably (and is probably built-in in better drives)



On Thu, 14 May 2015 10:38:43 -0400
Rick Lair r...@superiorroll.com wrote:


I have been following this thread somewhat, and have a question,

What is the difference between a line reactor and emi input filter?

We have a AD GS3 40hp drive in our turning center, and have the same 
noise problems with the drive, and I am not sure which one to buy, or do 
I need both? The drive schematic shows putting an emi filter on both 
sides of the drive, would that help as well? At $272 bucks a piece, I 
don't want to throw money away, but I do want to get this put to bed, we 
have been dealing with it for 2 years now, and I am getting tired of it.


Thanks

Rick

On 5/14/2015 9:53 AM, Dave Cole wrote:
 The Rasmi input filter
 Take it off and see what happens

 If that drive is screwing with your keyboard that is on the OUTSIDE of your 
control cabinet, imagine what kind of RF exposure is on the inside of your control 
cabinet!

 Those AD VFDs should also be sold as EMI test generators.  ;-)

 Dave



 On 5/14/2015 8:53 AM, Tom Easterday wrote:
 I spent some time with the spectrum analyzer but did??t have much luck in 
isolating the sink for the noise.  I just verified that my VFD does indeed produce a 
large amount of noise between low kHz and about 10MHz!  I did some re-routing of 
wires and replaced some that weren??t shielded.  I ordered some ferrites for the 
VFD-motor wiring and my computer I/O extension cabling which will be here in a couple 
days.

 However, I did find the source of the main problem!  It was indeed my 
keyboard.  Not the USB wiring from keyboard to pc, but the keyboard ITSELF is very 
sensitive to the noise created by the VFD.  If I move the keyboard to the very 
extreme end of it??s (rather long) usb cable the problem disappears completely. 6?? 
closer to the cabinet and noise reappears.  Apparently the noise is being interpreted 
as key presses by the keyboard circuitry.  I replaced the new water resistant 
Logitech keyboard with a very old Apple keyboard I had lying around and no more 
random characters!   I also had a second problem where the VFD would shut down 
somewhat randomly which I thought was related to this noise as well.  That turned out 
to be an over current condition at very low rpm.  Tweaking some settings fixed that.

 The Rasmi input filter, and various re-wiring and shielding I did was 
probably not needed, but in the long run perhaps it will save me from other problems.

 Thanks, for all the input,
 -Tom


 
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Rick Lair
Superior Roll  Turning LLC
399 East Center Street
Petersburg MI, 49270
PH: 734-279-1831
FAX: 734-279-1166
www.superiorroll.com


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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-14 Thread Karlsson Wang
I forgot to mention. There is a capacitance between motor cables and protective 
earth. Then the motor is driven by the VFD it is supplied with square wave 
voltages at high frequency and at each switching the capacitance is discharged 
or charged. As impedance at high frequency is far from zero in the power cables 
the ground will bounce around. If i think correctly both the protective and the 
rectified power ground will bounce around in opposite directions but I have 
never measured this.

The common mode impedance may be rised by adding a common mode inductur in the 
loop.

Nicklas Karlsson



On Thu, 14 May 2015 10:38:43 -0400
Rick Lair r...@superiorroll.com wrote:

 I have been following this thread somewhat, and have a question,
 
 What is the difference between a line reactor and emi input filter?
 
 We have a AD GS3 40hp drive in our turning center, and have the same 
 noise problems with the drive, and I am not sure which one to buy, or do 
 I need both? The drive schematic shows putting an emi filter on both 
 sides of the drive, would that help as well? At $272 bucks a piece, I 
 don't want to throw money away, but I do want to get this put to bed, we 
 have been dealing with it for 2 years now, and I am getting tired of it.
 
 Thanks
 
 Rick
 
 On 5/14/2015 9:53 AM, Dave Cole wrote:
  The Rasmi input filter
  Take it off and see what happens
 
  If that drive is screwing with your keyboard that is on the OUTSIDE of your 
  control cabinet, imagine what kind of RF exposure is on the inside of your 
  control cabinet!
 
  Those AD VFDs should also be sold as EMI test generators.  ;-)
 
  Dave
 
 
 
  On 5/14/2015 8:53 AM, Tom Easterday wrote:
  I spent some time with the spectrum analyzer but did’t have much luck in 
  isolating the sink for the noise.  I just verified that my VFD does indeed 
  produce a large amount of noise between low kHz and about 10MHz!  I did 
  some re-routing of wires and replaced some that weren’t shielded.  I 
  ordered some ferrites for the VFD-motor wiring and my computer I/O 
  extension cabling which will be here in a couple days.
 
  However, I did find the source of the main problem!  It was indeed my 
  keyboard.  Not the USB wiring from keyboard to pc, but the keyboard ITSELF 
  is very sensitive to the noise created by the VFD.  If I move the keyboard 
  to the very extreme end of it’s (rather long) usb cable the problem 
  disappears completely. 6” closer to the cabinet and noise reappears.  
  Apparently the noise is being interpreted as key presses by the keyboard 
  circuitry.  I replaced the new water resistant Logitech keyboard with a 
  very old Apple keyboard I had lying around and no more random characters!  
   I also had a second problem where the VFD would shut down somewhat 
  randomly which I thought was related to this noise as well.  That turned 
  out to be an over current condition at very low rpm.  Tweaking some 
  settings fixed that.
 
  The Rasmi input filter, and various re-wiring and shielding I did was 
  probably not needed, but in the long run perhaps it will save me from 
  other problems.
 
  Thanks, for all the input,
  -Tom
 
 
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 PH: 734-279-1831
 FAX: 734-279-1166
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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-14 Thread Gregg Eshelman
On 5/14/2015 6:53 AM, Tom Easterday wrote:

 However, I did find the source of the main problem!  It was indeed my 
 keyboard.  Not the USB wiring from keyboard to pc, but the keyboard ITSELF is 
 very sensitive to the noise created by the VFD.  If I move the keyboard to 
 the very extreme end of it’s (rather long) usb cable the problem disappears 
 completely. 6” closer to the cabinet and noise reappears.  Apparently the 
 noise is being interpreted as key presses by the keyboard circuitry.  I 
 replaced the new water resistant Logitech keyboard with a very old Apple 
 keyboard I had lying around and no more random characters!   I also had a 
 second problem where the VFD would shut down somewhat randomly which I 
 thought was related to this noise as well.  That turned out to be an over 
 current condition at very low rpm.  Tweaking some settings fixed that.

Good to know. Apparently Logitech takes the second part of 47 C.F.R. 
15.5 (b) literally.

... interference must be accepted that may be caused by the operation 
of an authorized radio station, by another intentional or unintentional 
radiator, by industrial, scientific and medical (ISM) equipment, or by 
an incidental radiator.

http://www.gpo.gov/fdsys/pkg/CFR-2014-title47-vol1/xml/CFR-2014-title47-vol1-sec15-5.xml

Your VFD is the incidental radiator. I'd be building a metal window 
screen box around it.

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-14 Thread Tom Easterday

 On May 14, 2015, at 4:15 PM, Peter C. Wallace p...@mesanet.com wrote:
 We found that common mode filters (big ferrite bead around U,V,W) on the 
 motor leads help a lot. Otherwise you have ~360V square waves driving the 
 stray wiring and motor capacitance and _nothing_ to limit the peak current of 
 these fast edges driving into this capacitance to ground. This causes huge 
 ground bumping of the VFD ground. A common mode choke limits these peak 
 currents considerably (and is probably built-in in better drives)

The GS2 VFD manual says that if you cannot have a ferrite wrapped on each lead, 
you can use 4 of them together to enclose the entire motor cable.  I don’t have 
extra wire to do them individually and my wire is a multi-conductor (3 + 
ground).  So I am going to put 4 ferrites together over the whole cable 
(including ground).  I hope that has the same or similar effect.  I am 
wondering if I will see any effect in the amplitude of the generated noise on 
the spectrum analyzer I have…?

-Tom


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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-14 Thread Tom Easterday
I don’t think the rule intends that you must react to it, or re-send it!  They 
may have taken it a bit too far ;-)
-Tom

 On May 14, 2015, at 7:51 PM, Gregg Eshelman g_ala...@yahoo.com wrote:
 
 On 5/14/2015 6:53 AM, Tom Easterday wrote:
 
 However, I did find the source of the main problem!  It was indeed my 
 keyboard.  Not the USB wiring from keyboard to pc, but the keyboard ITSELF 
 is very sensitive to the noise created by the VFD.  If I move the keyboard 
 to the very extreme end of it’s (rather long) usb cable the problem 
 disappears completely. 6” closer to the cabinet and noise reappears.  
 Apparently the noise is being interpreted as key presses by the keyboard 
 circuitry.  I replaced the new water resistant Logitech keyboard with a very 
 old Apple keyboard I had lying around and no more random characters!   I 
 also had a second problem where the VFD would shut down somewhat randomly 
 which I thought was related to this noise as well.  That turned out to be an 
 over current condition at very low rpm.  Tweaking some settings fixed that.
 
 Good to know. Apparently Logitech takes the second part of 47 C.F.R. 
 15.5 (b) literally.
 
 ... interference must be accepted that may be caused by the operation 
 of an authorized radio station, by another intentional or unintentional 
 radiator, by industrial, scientific and medical (ISM) equipment, or by 
 an incidental radiator.
 
 http://www.gpo.gov/fdsys/pkg/CFR-2014-title47-vol1/xml/CFR-2014-title47-vol1-sec15-5.xml
 
 Your VFD is the incidental radiator. I'd be building a metal window 
 screen box around it.
 
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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-13 Thread Dave Cole
I forgot to mention.   Automation Direct does allow returns up to 30 
days after the purchase, so if you try out the filter and it doesn't 
work..

Dave

On 5/12/2015 9:20 AM, Tom Easterday wrote:
 Thanks everyone for the great ideas.  I have a much fix now.  I will let you 
 know what I find.
 -Tom


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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-13 Thread Claude Zervas
I was getting similar symptoms - random stuff happening in Axis, windows
popping up, etc. - and it turned out it was just a cheap usb keyboard that
started malfunctioning and sending out random keystrokes. I replaced the
keyboard and everything is fine...

- Claude

On Wed, May 13, 2015 at 6:54 AM, Dave Cole linuxcncro...@gmail.com wrote:

 I forgot to mention.   Automation Direct does allow returns up to 30
 days after the purchase, so if you try out the filter and it doesn't
 work..

 Dave

 On 5/12/2015 9:20 AM, Tom Easterday wrote:
  Thanks everyone for the great ideas.  I have a much fix now.  I will let
 you know what I find.
  -Tom
 
 
 
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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-13 Thread TIM
I had suspected EMI as the cause of these symptoms as well, until last night 
when things got really bad. The spindle and axis motors were NOT running. 
I was simply trying to set up for a run. Most of the behavior seemed like mouse 
clicks into random locations in the Manual Control window of Axis (including 
multiple very disturbing 
activations of the spindle start button). I had these symptoms with a different 
USB mouse as well. I will change out the mouse again, but I smell a rat... 

--Tim 

- Original Message -

From: Claude Zervas cla...@utlco.com 
To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net 
Sent: Wednesday, May 13, 2015 11:19:21 AM 
Subject: Re: [Emc-users] If there's one thing I hate, all the noise, noise, 
noise, noise 

I was getting similar symptoms - random stuff happening in Axis, windows 
popping up, etc. - and it turned out it was just a cheap usb keyboard that 
started malfunctioning and sending out random keystrokes. I replaced the 
keyboard and everything is fine... 

- Claude 

On Wed, May 13, 2015 at 6:54 AM, Dave Cole linuxcncro...@gmail.com wrote: 

 I forgot to mention. Automation Direct does allow returns up to 30 
 days after the purchase, so if you try out the filter and it doesn't 
 work.. 
 
 Dave 
 
 On 5/12/2015 9:20 AM, Tom Easterday wrote: 
  Thanks everyone for the great ideas. I have a much fix now. I will let 
 you know what I find. 
  -Tom 
  
  
  
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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-12 Thread Karlsson Wang
Grounding. Power ground must be separated from small signal ground.

The VFD also generate a common mode voltage and unless a common mode inductor 
is added to increase common mode impedance there will be a high frequency 
current flowing thru the protected earth wire which in combination with the 
protected earth cable impedance at high frequency will make it bounce around. I 
know about two paths for the common mode voltage: capcitance inside the VFD to 
protected earth and between motor cables and protected earth.

Nicklas Karlsson



On Mon, 11 May 2015 21:00:39 -0400
Tom Easterday tom-...@bgp.nu wrote:

 Early on we made a decision to put our VFD into the same cabinet as the rest 
 of the electronics on a lathe retrofit - I originally had two separate 
 cabinets, one for power with vfd and one for electronics.  This was to save 
 space and bring the size of the cabinet on the machine down to a more 
 reasonable size so it might fit through doors, etc.  In retrospect, perhaps 
 that was a bad idea.  But here we are trying to address VFD induced noise 
 problems.   The cabinet is shown in a picture here:
 https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/
  
 https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/
   There is actually more wiring completed now then what is shown in the 
 picture but you get the idea.
 
 After having read about folks often using Rasmi input power filters to solve 
 noise issues I purchased one from ebay and installed it today.  It didn’t 
 help, and may have actually made the problem worse.  I installed it very 
 close to the VFD input power terminals as recommended.
 
 When I run the spindle motor on it’s lowest RPM I hear a high pitched whine 
 (at the motor) and strange things begin to happen in Axis.  Windows pop up, 
 perhaps a homing window, perhaps a touch off, perhaps Axis switches to MDI 
 mode, sometimes it turns the machine off, sometimes it turns the machine off 
 but the spindle keeps moving!   Sometimes the VFD shuts off and displays oL 
 1” on the screen.
 
 So now I want to understand how this noise is getting into the PC. I first 
 thought it was because the keyboard, mouse, and video cables ran past the VFD 
 in the cabinet and noise was being induced on the keyboard cable.  So in 
 trying to isolate where the issue was I disconnected those cables and ran 
 them far away from the VFD.  No help..  I then wondered if it was coming in 
 the AC power to the PC, so I rerouted the PC power to a completely different 
 outlet outside of the cabinet.  No help.  I then rerouted the network and 
 video cables to get those away from the VFD, no help again.   Even with the 
 door open (as you see in the picture) I have noise.  The only thing 
 connecting the PC to the rest of the system is the parallel cable which is 
 about 12” long that connects to the Mesa 7i85s card (and again, that is at 
 the other end of my cabinet from the VFD).  Today I borrowed a friend’s 
 0-1Ghz spectrum analyzer to see if I can find the source/frequency of the 
 noise and/or where it might be getting to the PC.  I will start playing with 
 that tomorrow.  
 
 I am wondering if anyone has any ideas of where i can look, or what I can do?
 -Tom
 
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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-12 Thread Mark Johnsen
I'm not the strongest electrically, but when I've run into noise issues, it
was either we did something obvious and we were able to fix it (like in the
non-grounded lathe example from Marius Liebenberg) or we never found the
problem.  We put on all kinds of ferrite torrids and inline filters and
they didn't do squat.  While they may work, I'm skeptical.

I think you said your issue was windows start to open and you get weird
behavior on the screen, it seems to be mouse, keyboard, or pc noise.  I see
a large 'wall wart' power supply that I'm assuming is powering the PC?
Maybe I missed the other PC power supply, but those wall warts
are usually un-grounded, so maybe try a standard PC power supply w/ a
ground on the power cord and to the PC.

Another thing to try might be how you have the Mesa card powered, I'm not
sure what Mesa board you have, but the 7i77 has jumpers for 5Vdc and you
can power from the PC or externally.  Maybe you've got noise on that 5V
rail back through the PC?

Lastly, running the mouse or keyboard cable near a power cable, especially
a noisy one, could cause what you're seeing.  I think you tried this one
already.

Mark
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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-12 Thread Dave Cole
One more thing...  I'd put the cover on that M350 computer chassis.   
That will help keep RF out of the computer.

Dave

On 5/11/2015 9:00 PM, Tom Easterday wrote:
 Early on we made a decision to put our VFD into the same cabinet as the rest 
 of the electronics on a lathe retrofit - I originally had two separate 
 cabinets, one for power with vfd and one for electronics.  This was to save 
 space and bring the size of the cabinet on the machine down to a more 
 reasonable size so it might fit through doors, etc.  In retrospect, perhaps 
 that was a bad idea.  But here we are trying to address VFD induced noise 
 problems.   The cabinet is shown in a picture here:
 https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/
  
 https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/
   There is actually more wiring completed now then what is shown in the 
 picture but you get the idea.

 After having read about folks often using Rasmi input power filters to solve 
 noise issues I purchased one from ebay and installed it today.  It didn’t 
 help, and may have actually made the problem worse.  I installed it very 
 close to the VFD input power terminals as recommended.

 When I run the spindle motor on it’s lowest RPM I hear a high pitched whine 
 (at the motor) and strange things begin to happen in Axis.  Windows pop up, 
 perhaps a homing window, perhaps a touch off, perhaps Axis switches to MDI 
 mode, sometimes it turns the machine off, sometimes it turns the machine off 
 but the spindle keeps moving!   Sometimes the VFD shuts off and displays oL 
 1” on the screen.

 So now I want to understand how this noise is getting into the PC. I first 
 thought it was because the keyboard, mouse, and video cables ran past the VFD 
 in the cabinet and noise was being induced on the keyboard cable.  So in 
 trying to isolate where the issue was I disconnected those cables and ran 
 them far away from the VFD.  No help..  I then wondered if it was coming in 
 the AC power to the PC, so I rerouted the PC power to a completely different 
 outlet outside of the cabinet.  No help.  I then rerouted the network and 
 video cables to get those away from the VFD, no help again.   Even with the 
 door open (as you see in the picture) I have noise.  The only thing 
 connecting the PC to the rest of the system is the parallel cable which is 
 about 12” long that connects to the Mesa 7i85s card (and again, that is at 
 the other end of my cabinet from the VFD).  Today I borrowed a friend’s 
 0-1Ghz spectrum analyzer to see if I can find the source/frequency of the 
 noise and/or where it might be getting to the PC.  I will start playing with 
 that tomorrow.

 I am wondering if anyone has any ideas of where i can look, or what I can do?
 -Tom

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-12 Thread Erik Christiansen
On 11.05.15 23:14, Tom Easterday wrote:
 I will do that tomorrow.  I wonder if using this tape to shield
 unshielded wire, like my VFD to motor cable, would work….?
 http://www.cesco.com/b2c/product/9770?utm_source=googleutm_medium=cpcutm_campaign=shoppingscid=scplp2640202gclid=CMTdkaSbu8UCFZeDaQodlRgAHQ

That or copper tape can be used for shielding, but still forms a coiled
inductor back to the cable ends, unless contact between turns is very
good. Can you run two tape lengths longitudinally, overlapping their
edges around the cable diameter, and stitching them into a
tube with frequent solder joints? Minimum impedance, at RF, back to your
star earth (from one end only) has to be good, after shutting it in.

Or, do you have some Al or Cu tubing in the junkbox, that you can bend
after pushing the cable through? If it's to hand, it's something you can
do without waiting for deliveries, and should work at least as well.
If it's primarily magnetic coupling, then steel tubing might be better.
Experimenting with a (mostly) closed steel box around the computer can
help determine that.

The power radiated is proportional to the open area between the two
power conductors. If they are twisted, e.g. one turn per inch, then that
is minimised, and there is less work for shielding to do.

My mini-ITX mobo is powered by a picoPSU, so can run off a 12v battery.
Thus isolating power entirely, and disconnecting the parport or other I/O
would allow checking whether Axis still plays up - proving that it is
radiated EMI. That may be hard to do there.

It'll be very interesting to hear what finally cures it.

Erik

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-12 Thread andy pugh
On 12 May 2015 at 02:00, Tom Easterday tom-...@bgp.nu wrote:
 I am wondering if anyone has any ideas of where i can look, or what I can do?

I had a similar (but much less serious) problem and one of the things
I did was to take the outgoing motor cables through a common-mode
choke. (ie all three wires go through the same ferrite toroid a few
times before continuing to the motor. The idea of this is that it
slows the rise-rate of the VFD chopper pulses and removes some of the
high-frequency content.
I suspect it is not a good idea to over-do this. I also don't know it
if helped, as I fitted an input filter at the same time.
It is interesting that the Mesa 8i20s I have all came with a clamp-on
toroid for the output wires supplied. (And the output toroid
suggestion came from PCW)

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-12 Thread Tom Easterday
Thanks everyone for the great ideas.  I have a much fix now.  I will let you 
know what I find.  
-Tom


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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-12 Thread Dave Cole
I have had very good luck with drive input filters sold by Automation 
Direct.On the box it says Delta Electronics  Model 20DRT1W3S.

Here it is.
http://www.automationdirect.com/adc/Shopping/Catalog/Drives/AC_Drive_%28VFD%29_Spare_Parts_-a-_Accessories/GS_EMI_-z-_RF_Filters/EMI_-z-_RF_Filters_%28All_GS_Drives%29/20DRT1W3S

This is a single phase in/out filter I installed on some Teco servo 
drives that were scrambling the Mesa boards on an analog servo 
application in a panel quite a bit larger than yours.
That black SO cord running from the top of the drive to the contactor (I 
think) is an excellent broadcast antenna that will induce voltages into 
other circuits.

I mounted the filter just above the drive so I had short leads from the 
filter to the drive.All problems vanished.

Can you run your motor leads in sealtite?   Get the metallic variety of 
course.   That should also work to shield your motor leads.

Automation Direct also sells output chokes which will cut down on noise 
on the motor leads.

Dave





On 5/11/2015 9:00 PM, Tom Easterday wrote:
 Early on we made a decision to put our VFD into the same cabinet as the rest 
 of the electronics on a lathe retrofit - I originally had two separate 
 cabinets, one for power with vfd and one for electronics.  This was to save 
 space and bring the size of the cabinet on the machine down to a more 
 reasonable size so it might fit through doors, etc.  In retrospect, perhaps 
 that was a bad idea.  But here we are trying to address VFD induced noise 
 problems.   The cabinet is shown in a picture here:
 https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/
  
 https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/
   There is actually more wiring completed now then what is shown in the 
 picture but you get the idea.

 After having read about folks often using Rasmi input power filters to solve 
 noise issues I purchased one from ebay and installed it today.  It didn’t 
 help, and may have actually made the problem worse.  I installed it very 
 close to the VFD input power terminals as recommended.

 When I run the spindle motor on it’s lowest RPM I hear a high pitched whine 
 (at the motor) and strange things begin to happen in Axis.  Windows pop up, 
 perhaps a homing window, perhaps a touch off, perhaps Axis switches to MDI 
 mode, sometimes it turns the machine off, sometimes it turns the machine off 
 but the spindle keeps moving!   Sometimes the VFD shuts off and displays oL 
 1” on the screen.

 So now I want to understand how this noise is getting into the PC. I first 
 thought it was because the keyboard, mouse, and video cables ran past the VFD 
 in the cabinet and noise was being induced on the keyboard cable.  So in 
 trying to isolate where the issue was I disconnected those cables and ran 
 them far away from the VFD.  No help..  I then wondered if it was coming in 
 the AC power to the PC, so I rerouted the PC power to a completely different 
 outlet outside of the cabinet.  No help.  I then rerouted the network and 
 video cables to get those away from the VFD, no help again.   Even with the 
 door open (as you see in the picture) I have noise.  The only thing 
 connecting the PC to the rest of the system is the parallel cable which is 
 about 12” long that connects to the Mesa 7i85s card (and again, that is at 
 the other end of my cabinet from the VFD).  Today I borrowed a friend’s 
 0-1Ghz spectrum analyzer to see if I can find the source/frequency of the 
 noise and/or where it might be getting to the PC.  I will start playing with 
 that tomorrow.

 I am wondering if anyone has any ideas of where i can look, or what I can do?
 -Tom

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[Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-11 Thread Tom Easterday
Early on we made a decision to put our VFD into the same cabinet as the rest of 
the electronics on a lathe retrofit - I originally had two separate cabinets, 
one for power with vfd and one for electronics.  This was to save space and 
bring the size of the cabinet on the machine down to a more reasonable size so 
it might fit through doors, etc.  In retrospect, perhaps that was a bad idea.  
But here we are trying to address VFD induced noise problems.   The cabinet is 
shown in a picture here:
https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/
 
https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/
  There is actually more wiring completed now then what is shown in the picture 
but you get the idea.

After having read about folks often using Rasmi input power filters to solve 
noise issues I purchased one from ebay and installed it today.  It didn’t help, 
and may have actually made the problem worse.  I installed it very close to the 
VFD input power terminals as recommended.

When I run the spindle motor on it’s lowest RPM I hear a high pitched whine (at 
the motor) and strange things begin to happen in Axis.  Windows pop up, perhaps 
a homing window, perhaps a touch off, perhaps Axis switches to MDI mode, 
sometimes it turns the machine off, sometimes it turns the machine off but the 
spindle keeps moving!   Sometimes the VFD shuts off and displays oL 1” on the 
screen.

So now I want to understand how this noise is getting into the PC. I first 
thought it was because the keyboard, mouse, and video cables ran past the VFD 
in the cabinet and noise was being induced on the keyboard cable.  So in trying 
to isolate where the issue was I disconnected those cables and ran them far 
away from the VFD.  No help..  I then wondered if it was coming in the AC power 
to the PC, so I rerouted the PC power to a completely different outlet outside 
of the cabinet.  No help.  I then rerouted the network and video cables to get 
those away from the VFD, no help again.   Even with the door open (as you see 
in the picture) I have noise.  The only thing connecting the PC to the rest of 
the system is the parallel cable which is about 12” long that connects to the 
Mesa 7i85s card (and again, that is at the other end of my cabinet from the 
VFD).  Today I borrowed a friend’s 0-1Ghz spectrum analyzer to see if I can 
find the source/frequency of the noise and/or where it might be getting to the 
PC.  I will start playing with that tomorrow.  

I am wondering if anyone has any ideas of where i can look, or what I can do?
-Tom

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-11 Thread Bruce Layne
I'm sorry to hear that the Rasmi filter didn't help your noise 
problems.  I bought four of them, and I've installed the first one but 
am 1-3 days away from finally installing that electrical panel and 
testing the electronics.

Without the Rasmi filter, my CNC router has some noise on the VGA 
monitor.  Sometimes it's barely noticeable, and sometimes it causes a 
lot of screen flicker.  It's VFD frequency (spindle speed) specific.  
Occasionally, it will blank the screen, which makes controlling the CNC 
router interesting.  I tried clamp on ferrite toroids on the VGA and 
monitor power cables and that helped a little.  The big problem is the 
way I ran several feet of the monitor cables adjacent to the spindle 
motor cable.  I knew better, but hoped the motor cable shielding would 
be sufficient.  I bought better quality double shielded VGA cable but 
haven't tried that yet.  I should rerun the spindle motor cable far away 
from any data cables.

The Rasmi filter is used to filter conducted noise.  It attenuates the 
electrical noise that might be conducted on the incoming power lines.  
The Rasmi filter does nothing to attenuate radiated noise that's 
broadcast by the VFD and the spindle motor cable.  This type of noise is 
analogous to a radio signal that's transmitted through the air, as 
opposed to being conducted on wires.  I suspect radiated noise might be 
a lot of your problem.  The spindle motor cable is a transmitting 
antenna.  All of those other wires in the panel are receiving antennas.

Good wiring practices can help, as you've already mentioned.  I route 
power cables in one wireway and data cables in other wireways.  It's a 
nonlinear world, so when a data cable needs to cross a power cable, have 
them cross at 90 degree angles and don't run them adjacent to each 
other.  Use shielded cable.  Shielded spindle motor cable will help 
prevent the VFD from transmitting radiated noise.  Shielded cable for 
sensitive data signals will help prevent them from receiving the 
radiated noise signals.  Shielding the noise source and the sensitive 
signals fights the noise at both ends.  Keep as much distance as 
possible between high current lines (particularly the spindle motor 
cable between the VFD and spindle motor as it has some high frequency 
switching noise that radiates very well).  Distance is your friend.  The 
electromagnetic coupling is in inverse proportion to the square of the 
distance between the receiver and transmitter.  Twice as close results 
in four times the noise.  Four times as close gets you sixteen times as 
much noise. Shielded twisted pair for data cables (like Cat5 ethernet 
cable) is particularly noise immune because the shield blocks a lot of 
the radiated noise, and the noise that makes it through is greatly 
attenuated by twisting the cable which greatly reduces the common mode 
noise in those lines.  Ground the cable shield at one end only.  
Usually, the shield is terminated at the source.  In the case of the 
spindle motor cable, I'd ground the shield in the electrical panel next 
to the VFD.  For most applications, I like a star grounding 
configuration where all of the grounds terminate at one common grounding 
post.  Scrape off any paint and use a star washer to bite into the metal 
and tighten it enough to make a good gas proof electrical connection 
that won't corrode in a year or so and cause a high impedance path to 
ground.  A single ground point prevents current loops, where there is a 
current flowing between two or more ground points.  In some special 
circumstances, you might have better results with a power ground and a 
data ground, or an analog ground and a digital ground.  With two 
completely separate ground systems, the low voltage electronics won't be 
subjected to a few volts of ground float noise from a noisy power device 
like a VFD.  If the two subsystems need to have a common reference 
voltage, the two ground systems can be connected by a resistor 
(typically 1K to 100K) and/or an RF choke to allow the common voltages 
of both subsystems to float to the same voltage while attenuating AC noise.

Pretty panel wiring is usually less noisy, particularly where radiated 
noise is concerned.

I hope that helps.

Good luck slaying the noise gremlins.





On 05/11/2015 09:00 PM, Tom Easterday wrote:
 Early on we made a decision to put our VFD into the same cabinet as the rest 
 of the electronics on a lathe retrofit - I originally had two separate 
 cabinets, one for power with vfd and one for electronics.  This was to save 
 space and bring the size of the cabinet on the machine down to a more 
 reasonable size so it might fit through doors, etc.  In retrospect, perhaps 
 that was a bad idea.  But here we are trying to address VFD induced noise 
 problems.   The cabinet is shown in a picture here:
 https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/
  
 

Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-11 Thread Gregg Eshelman

 On 05/11/2015 06:00 PM, Tom Easterday wrote:
 Early on we made a decision to put our VFD into the same cabinet as the rest 
 of the electronics on a lathe retrofit - I originally had two separate 
 cabinets, one for power with vfd and one for electronics.  This was to save 
 space and bring the size of the cabinet on the machine down to a more 
 reasonable size so it might fit through doors, etc.  In retrospect, perhaps 
 that was a bad idea.  But here we are trying to address VFD induced noise 
 problems.   The cabinet is shown in a picture here:
 https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/

Another thing, put the outer case back on the computer you have mounted 
to the door, or cover the large open holes with solid sheet metal or 
screen. That's as much to keep noise generated by the computer in as it 
is to keep interference out.


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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-11 Thread Tom Easterday

 On May 11, 2015, at 10:49 PM, Gregg Eshelman g_ala...@yahoo.com wrote:
 
 Another thing, put the outer case back on the computer you have mounted 
 to the door, or cover the large open holes with solid sheet metal or 
 screen. That's as much to keep noise generated by the computer in as it 
 is to keep interference out.


I will do that tomorrow.  I wonder if using this tape to shield unshielded 
wire, like my VFD to motor cable, would work….?  
http://www.cesco.com/b2c/product/9770?utm_source=googleutm_medium=cpcutm_campaign=shoppingscid=scplp2640202gclid=CMTdkaSbu8UCFZeDaQodlRgAHQ
 
http://www.cesco.com/b2c/product/9770?utm_source=googleutm_medium=cpcutm_campaign=shoppingscid=scplp2640202gclid=CMTdkaSbu8UCFZeDaQodlRgAHQ

-Tom

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-11 Thread Rafael Skodlar
Tom,

Hard to tell from the picture but I would make sure that ground is 
properly connected in star configuration, i.e. there is only one 
ground point [1] in the cabinet and the CNC machine. I suspect you get 
some ground currents somewhere which possibly cause enough noise to mess 
up your VFD.

[1] ground could be a copper bar with enough holes to attach all ground 
wires from all cables, CNC chassis, and power filter to it. Connect 
ground wire to the door itself and whatever is mounted on it as well.

It might be worthwhile to add ferrite toroids on critical (analog) lines 
including parallel cable; see 
https://en.wikipedia.org/wiki/Toroidal_inductors_and_transformers

On 05/11/2015 06:00 PM, Tom Easterday wrote:
 Early on we made a decision to put our VFD into the same cabinet as the rest 
 of the electronics on a lathe retrofit - I originally had two separate 
 cabinets, one for power with vfd and one for electronics.  This was to save 
 space and bring the size of the cabinet on the machine down to a more 
 reasonable size so it might fit through doors, etc.  In retrospect, perhaps 
 that was a bad idea.  But here we are trying to address VFD induced noise 
 problems.   The cabinet is shown in a picture here:
 https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/
  
 https://www.flickr.com/photos/37438950@N00/17219261571/in/album-72157651167328249/
   There is actually more wiring completed now then what is shown in the 
 picture but you get the idea.

 After having read about folks often using Rasmi input power filters to solve 
 noise issues I purchased one from ebay and installed it today.  It didn’t 
 help, and may have actually made the problem worse.  I installed it very 
 close to the VFD input power terminals as recommended.

 When I run the spindle motor on it’s lowest RPM I hear a high pitched whine 
 (at the motor) and strange things begin to happen in Axis.  Windows pop up, 
 perhaps a homing window, perhaps a touch off, perhaps Axis switches to MDI 
 mode, sometimes it turns the machine off, sometimes it turns the machine off 
 but the spindle keeps moving!   Sometimes the VFD shuts off and displays oL 
 1” on the screen.

 So now I want to understand how this noise is getting into the PC. I first 
 thought it was because the keyboard, mouse, and video cables ran past the VFD 
 in the cabinet and noise was being induced on the keyboard cable.  So in 
 trying to isolate where the issue was I disconnected those cables and ran 
 them far away from the VFD.  No help..  I then wondered if it was coming in 
 the AC power to the PC, so I rerouted the PC power to a completely different 
 outlet outside of the cabinet.  No help.  I then rerouted the network and 
 video cables to get those away from the VFD, no help again.   Even with the 
 door open (as you see in the picture) I have noise.  The only thing 
 connecting the PC to the rest of the system is the parallel cable which is 
 about 12” long that connects to the Mesa 7i85s card (and again, that is at 
 the other end of my cabinet from the VFD).  Today I borrowed a friend’s 
 0-1Ghz spectrum analyzer to see if I can find the source/frequency of the 
 noise and/or where it migh
t be getting to the PC.  I will start playing with that tomorrow.

 I am wondering if anyone has any ideas of where i can look, or what I can do?
 -Tom

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-11 Thread Gregg Eshelman
Either move the VFD to its own enclosure or isolate it with sheet metal 
and metal screening, grounded to the enclosure. That will block RFI/EMI 
radiating directly from the VFD.

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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-11 Thread Tom Easterday
Thanks for all the info Bruce!  I suspect you are right that it is radiated 
noise.  I should probably start with the outbound motor wire from the VFD.  It 
is about 5 ft. long and not shielded.   There are also a couple other cables I 
can shield as well that current aren’t.
-Tom


 On May 11, 2015, at 10:05 PM, Bruce Layne linux...@thinkingdevices.com 
 wrote:
 
 I'm sorry to hear that the Rasmi filter didn't help your noise 
 problems.  I bought four of them, and I've installed the first one but 
 am 1-3 days away from finally installing that electrical panel and 
 testing the electronics.
 
 Without the Rasmi filter, my CNC router has some noise on the VGA 
 monitor.  Sometimes it's barely noticeable, and sometimes it causes a 
 lot of screen flicker.  It's VFD frequency (spindle speed) specific.  
 Occasionally, it will blank the screen, which makes controlling the CNC 
 router interesting.  I tried clamp on ferrite toroids on the VGA and 
 monitor power cables and that helped a little.  The big problem is the 
 way I ran several feet of the monitor cables adjacent to the spindle 
 motor cable.  I knew better, but hoped the motor cable shielding would 
 be sufficient.  I bought better quality double shielded VGA cable but 
 haven't tried that yet.  I should rerun the spindle motor cable far away 
 from any data cables.
 
 The Rasmi filter is used to filter conducted noise.  It attenuates the 
 electrical noise that might be conducted on the incoming power lines.  
 The Rasmi filter does nothing to attenuate radiated noise that's 
 broadcast by the VFD and the spindle motor cable.  This type of noise is 
 analogous to a radio signal that's transmitted through the air, as 
 opposed to being conducted on wires.  I suspect radiated noise might be 
 a lot of your problem.  The spindle motor cable is a transmitting 
 antenna.  All of those other wires in the panel are receiving antennas.
 
 Good wiring practices can help, as you've already mentioned.  I route 
 power cables in one wireway and data cables in other wireways.  It's a 
 nonlinear world, so when a data cable needs to cross a power cable, have 
 them cross at 90 degree angles and don't run them adjacent to each 
 other.  Use shielded cable.  Shielded spindle motor cable will help 
 prevent the VFD from transmitting radiated noise.  Shielded cable for 
 sensitive data signals will help prevent them from receiving the 
 radiated noise signals.  Shielding the noise source and the sensitive 
 signals fights the noise at both ends.  Keep as much distance as 
 possible between high current lines (particularly the spindle motor 
 cable between the VFD and spindle motor as it has some high frequency 
 switching noise that radiates very well).  Distance is your friend.  The 
 electromagnetic coupling is in inverse proportion to the square of the 
 distance between the receiver and transmitter.  Twice as close results 
 in four times the noise.  Four times as close gets you sixteen times as 
 much noise. Shielded twisted pair for data cables (like Cat5 ethernet 
 cable) is particularly noise immune because the shield blocks a lot of 
 the radiated noise, and the noise that makes it through is greatly 
 attenuated by twisting the cable which greatly reduces the common mode 
 noise in those lines.  Ground the cable shield at one end only.  
 Usually, the shield is terminated at the source.  In the case of the 
 spindle motor cable, I'd ground the shield in the electrical panel next 
 to the VFD.  For most applications, I like a star grounding 
 configuration where all of the grounds terminate at one common grounding 
 post.  Scrape off any paint and use a star washer to bite into the metal 
 and tighten it enough to make a good gas proof electrical connection 
 that won't corrode in a year or so and cause a high impedance path to 
 ground.  A single ground point prevents current loops, where there is a 
 current flowing between two or more ground points.  In some special 
 circumstances, you might have better results with a power ground and a 
 data ground, or an analog ground and a digital ground.  With two 
 completely separate ground systems, the low voltage electronics won't be 
 subjected to a few volts of ground float noise from a noisy power device 
 like a VFD.  If the two subsystems need to have a common reference 
 voltage, the two ground systems can be connected by a resistor 
 (typically 1K to 100K) and/or an RF choke to allow the common voltages 
 of both subsystems to float to the same voltage while attenuating AC noise.
 
 Pretty panel wiring is usually less noisy, particularly where radiated 
 noise is concerned.
 
 I hope that helps.
 
 Good luck slaying the noise gremlins.


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Re: [Emc-users] If there's one thing I hate, all the noise, noise, noise, noise

2015-05-11 Thread Bruce Layne
Replacing the unshielded spindle motor cable with a shielded cable and 
grounding the shield in the electrical panel is probably going to yield 
the maximum bang for the buck.

Your DIN rail mounted ground terminals in the bottom of your panel are a 
good single point ground for a star configured grounding scheme, IMO.  
The only hassle might be getting the shield from the VFD cable down there.

I think you were smart to put the VFD on the right side of the 
electrical panel and the PC on the left side.  As I previously 
mentioned, with radiated noise, distance is your friend.  If you're 
getting noise inside the PC, you might want to put a cover on the PC 
enclosure.  My CNC panels use bare motherboards mounted to the subpanel, 
but some shielding is good.

BTW - Electromagnetic radiated noise has an electric field and a 
magnetic field.  Sometimes you'll seem to have more of one than 
another.  Aluminum will block an electric field but isn't as good at 
attenuating a magnetic field.  A steel panel attenuates magnetic fields 
better.  Mu metal is the best electromagnetic shielding but typically 
isn't practical for this sort of problem.  You can use a couple of small 
C clamps to hold sheet metal over an open chassis hole to do a real 
world test to determine how effective it'll be before spending time 
fabricating a cover only to learn that it doesn't reduce the noise.

I also liked your comment about using a spectrum analyzer to quantify 
the noise.  Noise problems can be counter intuitive and it's difficult 
to fix a problem if you don't know what it is, or even where it is.  If 
good wiring practices result in intolerable noise, I might sprinkle a 
few magic ferrite beans around in a blind attempt to fix a specific 
problem, but if that doesn't work I'll quickly proceed to step 2, which 
involves the digital storage oscilloscope.

/“When you can measure what you are speaking about, and express it in 
numbers, you know something about it, when you cannot express it in 
numbers, your knowledge is of a meager and unsatisfactory kind; it may 
be the beginning of knowledge, but you have scarcely, in your thoughts 
advanced to the stage of science.”//
//
//   - Lord Kelvin//
/




On 05/11/2015 10:44 PM, Tom Easterday wrote:
 Thanks for all the info Bruce!  I suspect you are right that it is radiated 
 noise.  I should probably start with the outbound motor wire from the VFD.  
 It is about 5 ft. long and not shielded.   There are also a couple other 
 cables I can shield as well that current aren’t.
 -Tom



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