Update and an issue. Good news is that VFD is working great as it should. I had some one way communication problems which mysteriously went away and it has been solid since.
Now warning: When I first took the unit apart to see what the IGBT par number was I fatigued the capacitor bank connecting wire which later burned off and I am surprised that the unit survived. It actually ran for a while and then started sparking, shut off and went into error mode anytime I tried powering it. The connecting wire is a solid copper wire which must have been fatigued cause I was careful. Anyway, replaced it with a multi-strand wire and things are good.
I also installed the Q23 IGBT but while doing so I realized that my unit is missing the opto as others have reported, so I'll have to get that and give it a try.
I do have another problem that I don't know how to troubleshoot I thought maybe it is VFD related.
I milled few parts yesterday with VFD without any issues, it is nice to have automatic spindle control, set the speed turns it on and off; less stuff to remember. Today I wanted to try taping cycles and ran into a problem. I'm air cutting, the tap goes down properly, at the bottom spindle stops, tap comes up some fixed height, spindle starts up in reverse direction mach waits for the spindle to spin-up and this is where the stepper on the z-axis starts buzzing and sits in one spot as if it was mechanically blocked. I am completely stumped.
This is what I have done so far in trying to troubleshoot the problem.
Disabled VFD plug-in and run the program with spindle at standstill, the z-axis goes up and down as expected. It seems that running the motor in reverse somehow corrupts stepper drive. It sort of behaves like stepper gets both forward and reverse signals.
Is this VFD noise getting into my stepper drives?
I also tried shielding the VFD to motor cable and the VFD it self, also added ferrite clamp to the drive powwr line without any difference.
Is there any way that MACH is issuing wrong command to the stepper drive when the plug-in is enabled?