Thanks, let's see if this helps...
I'm still investigating the bug that I have in hand, I have to say that all my equipment has worked perfectly before finishing mounting all the electronics in a box.
The conclusion I have reached from the tests carried out is that the VF introduces electrical noise and makes the system go out of control in an extremely rare way, I insist that this has not happened to me before and the same components have been working perfectly, to say that I have the cables shielded and with a ground connection at one end of each cable harness, the negative poles of the sources are not connected to each other or grounded, I have tested the ferrite core that brings the VF to both the AC input As for the U-V-W output that goes to the spindle motor, I have finally managed to remove the VF from the box and move it about 60cm away from it to see if I could isolate it enough with this.
The fact is that if I run the programs with the VF in RUN and at any speed (from S9000 to S24000) the axis positioning control fails, it is not that pulses are lost because the motors do what appears in the DRO, the problem is that, it is as if the program sends to other coordinates without being like that because the program has and visualizes the original and correct coordinates but the motors do not go there, now well, with the VF on but in STOP, that is, I comment the lines start (M03) and speed (S*********xx) of the spindle so the motor does not start but the program runs normally, because the whole program WORKS perfectly, it NEVER fails!!! I have also tried removing the cable from the spindle, leaving it in the air and separated from the rest of the cables and electronics and I can't remove the fault, but now the best is here!!!!....
If I load the program for normal operation, everything connected correctly, I adjust the 0 part for X, Y and Z, and before starting cycles, I press the "GOTO Z" key on the MACH3 screen, and with it all the axes go to 0 (if I have moved them to remove the probe for example) including the Z that goes down to the same piece, then YES !!!! the program works perfectly, the axes, the dimensions, the milling.... EVERYTHING, it works without any error if I press this key, if I don't press it it doesn't work...
?
I'm running out of ideas, I can only think of putting one of these filters
https://inverterdrive.com /group/EMC-Filters/Universal-Motors-FLT-PS2010L-C-G/ for the VFs that go to the input (220VAC), but on the other hand I am totally confused that if I click on "GOTO Z" it does work and it is not affected by possible electrical interference.
Please, does anyone have an idea that I could try or have an explanation for this?
Here are some photos of my installation. Greetings.