didn't think to check s/stepper config. 

i notice there is a spindle check box for pwm within the s-s config.

i have checked that as it was unchecked and made base pwm 50 as that figure is mentioned in the DC03 setup for mach 3.  not sure i have this right. 

didn't make a difference.  i assume i am checking this all correctly.

what i have doing is turning the spindle on via F5 or m3s1000 and by this stage i have a selected a pulley from the pulley list.  lets say a pulley with a min 500 max1000.  once the spindle is running (i only ever get max volt output from the dc03) i use the spindle +/- buttons to see if hte rpm changes.  the numbers on the screen go up or down but the spindle doesn't change.

i have no spindle feedback yet.  one crisis at a time.
attached is the newest xml

Ok I am not sure if the plugin config is showing correctly as I dont have an ESS here but seems you have the spindle set to Relay or None rather than PWM.
See screenshot below
Hood

Edit
 I have just noticed you have another reply which was on the next page so I didnt see it
Will have another look at your xml.

In that latest plugin you still have it as the screenshot above.  you have changed the Hz but still not chosen the PWM.
Hood

thats odd cause when i open up mach3 this is what the plug in screen looks like

tried with the settings in the pic but no joy

Ok if that is correct in your xml then possibly you sent a previous xml before it had been saved.
Ok go to Config menu then Motor Tuning, click Spindle and.
Set the Steps per to 1000
Velocity to 60
Accel to 1
Then Save Axis button.

See if you get  any results with these settings.
Hood

Have changed as per your instruction but still no good. Just goes straight to max rpm on start up

Double checked the above screen and it does open with the Pwm box checked in the plug in

Thanks for the help btw

Cant think what else could be the problem if you definitely have the DC03 connected to pin 1 port 1 of the SS and the rest of the DC03 wiring is correct it should at least give you some sort of control with these settings.
Hood

The dc 03 is connected via the same bob as the axis motor outputs. When I disconnect the step wire to the dc03 the led changes from a fast flash to a slow flash and according to the manual a slow flash indicates no activity to the dc03 input. I get the sakes result when I change the active low step to an active high step on the spindle motor out put

This tells me there is some sort of signal going to the dc03 but what type of signal I have no idea

Ok, seems like its right as far as wiring is concerned. Do you have a scope? If so you could check the output from the ESS. If no scope then possibly a multimeter set to DC V would work, the faster you command the spindle the higher the voltage should be.
Hood

ok i will give it a go.

should have added to my previous reply that when the led is slow flashing (no signal on input) the spindle turns at the min hts value that i have programed into the inverter (20htz)

i assume that when i turn the spindle on (f5) the spindle will start and run at min speed (20htz) until i either asjust the override +/- or type  S*** to increase the speed