I just finished installing a Spidle today.
Earlier today while simply testing this morning it seemed to fine.
Now it won't turn on.
I have touched nothing and the log file below has me baffled as to what is going on....
It is a Hitachi VFD/G540/ESS Smoothstepper.
Anyone have an idea why I'm getting this error???


2021-10-10 19:50:28.728 - >>> ESS PID - RPM: 0.0     PWM: 100.0000%     Error Now: 1.0000
2021-10-10 19:50:31.835 - >>> ESS PID - RPM: 0.0     PWM: 100.0000%     Error Now: 1.0000
2021-10-10 19:50:32.713 - API: mcCntlMdiExecute(inst = 0, commands = 's24000') (Mach4GUI)
2021-10-10 19:50:32.813 - Attempt transition from "Idle" on event "MDI Start" controller.cpp:2187
2021-10-10 19:50:32.813 - S_IDLE_on_exit
2021-10-10 19:50:32.814 - ACTION_start_mdi
2021-10-10 19:50:32.814 - S_MDI_RUNNING_on_entry
2021-10-10 19:50:32.815 - S_MDI_RUNNING2_on_entry
2021-10-10 19:50:32.816 - Signal id 1114, (Gcode Running), changed from LOW to HIGH.
2021-10-10 19:50:32.828 - 
2021-10-10 19:50:32.828 -    >>> ESS: PWM Mode - 'Spindle Motor Dir' set to Forward.
2021-10-10 19:50:32.828 - >>> ESS: Setting spindle to 24000.0 RPM or 100.0%. Range 0 PWM Base Freq = 400
2021-10-10 19:50:32.828 - >>> ESS: Spindle PID Activated.  Kp = 0.0000    Ki = 0.0000    Kd = 0.0000
2021-10-10 19:50:32.929 - Attempt transition from "MDI Running" on event "Stop" gcodeexec.cpp:1232
2021-10-10 19:50:32.929 - S_MDI_RUNNING2_on_exit
2021-10-10 19:50:32.929 - Signal id 1114, (Gcode Running), changed from HIGH to LOW.
2021-10-10 19:50:32.929 - S_MDI_RUNNING_on_exit
2021-10-10 19:50:32.929 - ACTION_stop
2021-10-10 19:50:32.954 - S_IDLE_on_entry
2021-10-10 19:50:34.948 - >>> ESS PID - RPM: 0.0     PWM: 100.0000%     Error Now: 1.0000
2021-10-10 19:50:38.056 - >>> ESS PID - RPM: 0.0     PWM: 100.0000%     Error Now: 1.0000
2021-10-10 19:50:41.160 - >>> ESS PID - RPM: 0.0     PWM: 100.0000%     Error Now: 1.0000
2021-10-10 19:50:44.271 - >>> ESS PID - RPM: 0.0     PWM: 100.0000%     Error Now: 1.0000
2021-10-10 19:50:47.377 - >>> ESS PID - RPM: 0.0     PWM: 100.0000%     Error Now: 1.0000
2021-10-10 19:50:50.484 - >>> ESS PID - RPM: 0.0     PWM: 100.0000%     Error Now: 1.0000

Hi,
looking at the log suggests you are using the ESS PID? Why? Do you need it?

In the first instance I would try just open loop, when you can get that to reliably operate THEN have a go at PID.

This is from your log:

2021-10-10 19:50:32.828 - >>> ESS: Spindle PID Activated.  Kp = 0.0000    Ki = 0.0000    Kd = 0.0000
If you have Kp, Ki and Kd all set to zero its no bloody wonder the PID loop won't work!

Craig

I did turn off the PID Loop, I agree after reading further I have no use for it.
Spindle still won't run.
Here is current log.

2021-10-11 19:22:45.839 - API: mcCntlMdiExecute(inst = 0, commands = 'm3 s20000
') (unknown caller)
2021-10-11 19:22:45.940 - Attempt transition from "Idle" on event "MDI Start" controller.cpp:2364
2021-10-11 19:22:45.940 - S_IDLE_on_exit
2021-10-11 19:22:45.940 - Signal id 1172, (Machine Idle), changed from HIGH to LOW.
2021-10-11 19:22:45.940 - ACTION_start_mdi
2021-10-11 19:22:45.941 - SoftSync()! Clearing planner.
2021-10-11 19:22:45.962 - S_MDI_RUNNING_on_entry
2021-10-11 19:22:45.962 - SoftSync()! Clearing planner. stateinterface.cpp:1351
2021-10-11 19:22:45.962 - S_MDI_RUNNING2_on_entry
2021-10-11 19:22:45.962 - Signal id 1114, (Gcode Running), changed from LOW to HIGH.
2021-10-11 19:22:45.963 - 
2021-10-11 19:22:45.963 - -----===== Mach4 build 4.2.0.4612, ESS build 277 =====-----
2021-10-11 19:22:45.963 - 
2021-10-11 19:22:45.963 - !!!!W9_HC/VERSION Register HANDLE FAILURE  !!!!!!
2021-10-11 19:22:45.977 - 
2021-10-11 19:22:45.977 -    >>> ESS: PWM Mode - 'Spindle Motor Dir' set to Forward.
2021-10-11 19:22:45.977 - >>> ESS: Setting spindle to 20000.0 RPM or 83.3%. Range 0 PWM Base Freq = 400
2021-10-11 19:22:45.977 - >>> ESS: Spindle PID is not enabled.
2021-10-11 19:22:45.978 - Signal id 1142, (Spindle Fwd), changed from HIGH to LOW.
2021-10-11 19:22:45.978 - 
2021-10-11 19:22:45.978 -    >>> ESS: PWM Mode - 'Spindle Motor Dir' set to Forward.
2021-10-11 19:22:45.978 - >>> ESS: Setting spindle to 20000.0 RPM or 83.3%. Range 0 PWM Base Freq = 400
2021-10-11 19:22:45.978 - >>> ESS: Spindle PID is not enabled.
2021-10-11 19:22:45.978 - Signal id 1142, (Spindle Fwd), changed from LOW to HIGH.
2021-10-11 19:22:45.979 - Waiting 0.000000 seconds for spindle at speed... spindle.cpp:300
2021-10-11 19:22:45.979 - Done. spindle.cpp:305
2021-10-11 19:22:46.081 - Attempt transition from "MDI Running" on event "Stop" gcodeexec.cpp:1359
2021-10-11 19:22:46.081 - S_MDI_RUNNING2_on_exit
2021-10-11 19:22:46.081 - Signal id 1114, (Gcode Running), changed from HIGH to LOW.
2021-10-11 19:22:46.081 - S_MDI_RUNNING_on_exit
2021-10-11 19:22:46.081 - ACTION_stop
2021-10-11 19:22:46.104 - API: mcMotionSetStill(inst = 0, motor = 0) (Called by ESS)
2021-10-11 19:22:46.104 - SetStill(): Motor 0 last position reported = 0.0000 controller.cpp:1400
2021-10-11 19:22:46.104 - All motors marked as still.
2021-10-11 19:22:46.139 - S_IDLE_on_entry
2021-10-11 19:22:46.140 - >>>--- ESS: Reporting Stopped: Motor 0 0.000000   #B
2021-10-11 19:22:46.140 - API: mcMotionSetStill(inst = 0, motor = 1) (Called by ESS)
2021-10-11 19:22:46.140 - SetStill(): Motor 1 last position reported = 0.0000 controller.cpp:1400
2021-10-11 19:22:46.140 - All motors marked as still.
2021-10-11 19:22:46.140 - >>>--- ESS: Reporting Stopped: Motor 1 0.000000   #B
2021-10-11 19:22:46.140 - API: mcMotionSetStill(inst = 0, motor = 2) (Called by ESS)
2021-10-11 19:22:46.140 - SetStill(): Motor 2 last position reported = 0.0000 controller.cpp:1400
2021-10-11 19:22:46.140 - All motors marked as still.
2021-10-11 19:22:46.145 - Signal id 1172, (Machine Idle), changed from LOW to HIGH.
2021-10-11 19:22:46.145 - >>>--- ESS: Reporting Stopped: Motor 2 0.000000   #B
2021-10-11 19:22:46.145 - API: mcMotionSetStill(inst = 0, motor = 3) (Called by ESS)
2021-10-11 19:22:46.145 - SetStill(): Motor 3 last position reported = 0.0000 controller.cpp:1400
2021-10-11 19:22:46.146 - All motors marked as still.
2021-10-11 19:22:46.146 - >>>--- ESS: Reporting Stopped: Motor 3 0.000000   #B
2021-10-11 19:22:46.146 - API: mcMotionSetStill(inst = 0, motor = 4) (Called by ESS)
2021-10-11 19:22:46.146 - SetStill(): Motor 4 last position reported = 0.0000 controller.cpp:1400
2021-10-11 19:22:46.146 - All motors marked as still.
2021-10-11 19:22:46.146 - >>>--- ESS: Reporting Stopped: Motor 4 0.000000   #B
2021-10-11 19:22:46.146 - API: mcMotionSetStill(inst = 0, motor = 5) (Called by ESS)
2021-10-11 19:22:46.146 - SetStill(): Motor 5 last position reported = 0.0000 controller.cpp:1400
2021-10-11 19:22:46.146 - All motors marked as still.
2021-10-11 19:22:46.146 - >>>--- ESS: Reporting Stopped: Motor 5 0.000000   #B

Hi,
how and with what signals are you turning on the spindle? Have you tested the output pin of the BoB to make sure its changing state?
How about the PWM? Is it establish a vary DC voltage at the output of the BoB?

Craig

I'm using a G540 to control the spindle.
So you are stating I should check that the G540 is outputting a PWM signal and turning the spindle on & off. How do you check? With a multimeter?
Should the "Spindle On" output be used in the ports and pins configuration on the ESS or just the Spindle PWM?
Currently I have the Spindle PWM and Spindle On assigned to output pins. Both Active High as noted with a Red "X".

Hi,

So you are stating I should check that the G540 is outputting a PWM signal and turning the spindle on & off. How do you check? With a multimeter?

Yes.

Should the "Spindle On" output be used in the ports and pins configuration on the ESS or just the Spindle PWM?

Both. Most spindles require an ON/OFF signal in addition to the 0-10V PWM. I assume you have programmed your VFD to accept voltage
PWM as primary control source?

Should the "Spindle On" output be used in the ports and pins configuration on the ESS or just the Spindle PWM?

On the G540 the SpindleOn input and PWM input are on specific pins. Have you assigned the ESS port  and pin the match the G540 input?

Craig

Another thing I just discovered and maybe why I thought it worked correctly yesterday...
If I start the spindle from my VFD front panel "Run" button and then go to Mach4 I can then take control of operation of the spindle RPM and turn the spindle on and off as much as I would like!
Very strange so I think it is a simple setting I don't understand in Mach4 to get the spindle to start on say an M3 S24000 MDI Command.

you have to change the settings in the vfd to accept computer inputs , they may call it something else. but if you can turn it on and off the panel on the vfd then you have it set to that panel not to be controlled thru Mach check your vfd manual. there is usually an input you need to change

How is it that? Once it is running I can then control it in Mach4?
So it doesn't seem like I need to change any setting in the VFD.
I have it set to be controlled by Analog Voltage 0-10VDC input.
It is a Hitachi WJ200-022SF if it matters.

I've seen where some people use a relay to turn the VFD spindle on and off is the necessary in my case as well? But also thought I read somewhere this is not necessary for a G540.

Hi,
most VFDs have an on/off input, usually from the factory from the touch panel on the VFD. Likewise the primary frequency source is from the touch panel.
Its necessary therefore to change the internal VFD settings such that the analog voltage input is the primary frequency source and the digital input
be the primary on/off signal.

Craig