I've been have a issue for the last 3 month that randomly started and I can resolve, previous to this it was running great for 6 months.

I use Veteric aspire form my tool paths and to generate my Gcode, I use the ATC arc for my post processor.

When the tool path is complete the spindle is supposed to stop for the tool change but it doesn't it just throws a estop alert, not every time but 90% of the time.

I have to turn the VFD off and on then I can continue.

Ive tried turning the debounce up, its currently at 4000 but am out of ideas now.

I'm running windows 10 and mach 3 R3.043 (can confirm this tomorrow when in the workshop)

Tempted the do a reinstall mach 3 maybe something has become corrupted (I am quite clueless in windows used Macs for the last 15 years) or maybe reinstall the whole system?

any help will greatly be appreciated 

Hi,
I suspect that when the spindle is being called to stop that it is generating a voltage spike which is causing the Estop.

When the spindle is spinning and then stopped as the spindle winds down it is a generator and can generate back into the power supply.

What is the spindle? How is it driven? Do you have agressive acceleration/deceleration setting for the spindle? Does it have a braking resistor?

Craig

the spindle is a Huanyang controlled by a VFD.

the acceleration/deceleration is not aggressive takes about 5-10 seconds to come to a stop.

I don't think it has a breaking resistor, im not to knowledgeable about the fine detail to be honest.

what would this issue randomly start?

I was thinking maybe the USB to RS485 Converter I use to control the spindle might be playing up?

Hi,
this is just my guess but as the spindle starts to decelerate a voltage spike occurs and that is somehow being coupled into your Estop circuit.
Given that it is an electromagnetic process it may well occur randomly.

Try a very long time constant debounce on you Estop circuit, or maybe even disconnect it altogether....does it change anything?

Craig

I'll try removing the estop to see if the resolves the issue.

Showing how little I know about mach3 now,

Would a high debounce time cause any issues for the homing/limite switches?

what sort of value for debounce is thought of as standard?

Hi,

Would a high debounce time cause any issues for the homing/limite switches?

Debounce is applied to each individual input. If you applied excessive debounce to either homing or limit switches then yes it will effect the response of homing
and/or limits. The debounce on the EStop input would have no effect on homing/limits.

what sort of value for debounce is thought of as standard?

There is no standard. The general rule is to use the minimum necessary to get good results. If that requires excessive filtering (debounce) then that means you have a problem
elsewhere interfering with your circuit and you are just using filtering to cover another fault.

Craig

I have tried all the above with no joy.

The issue has actually got worse.
When ever the spindle powers up the estop alert is triggered and the system stops.

On the diagnostics screen the estop light dose not illuminate when its triggered.

I have gone through all the wiring and all is sound.

I've moved the VFD and spindle cable away from all other cabling.
I've even tried running the VFD from a different circuit on the consumer board.
All the above have given the same result.

I have ordered an replacement USB to RS485 Converter that the spindle is controlled by.

Would reinstalling mach3 help? or even reinstalling windows?

Hi,

Would reinstalling mach3 help? or even reinstalling windows?

By all means try but I think it will make no difference at all. If the system Estops every time the VFD starts or stops then its an electrical noise issue.

Craig

Ive been problem solving some more.

It seems that mach3 its getting a response from the VFD as such its showing the estop alert.

Ive got a new USB to RS485 adapter and still getting the same response.

I have reset the VFD and re programmed it, manually starting, stopping and changing the speed all functions correctly.

I've also used spindle talker 2 to see if the VFD is reporting back and its not getting a response.

Dose anyone know when the VFD would stop reporting back?

Could there be a fault with the VFD?



 

So after more problem solving I've come to the conclusion the VFD has decided to like being controlled by mach 3.

I've had the Cnc running perfectly again today, I just have to set the spindle speed and turn the spindle on and off myself.

This along with spindle talker not being about to communicate with the VFD, changing the USB to rs485 adapter has lead me to believe the VFD is my issue.

Mach3 not getting a response from the VFD I think is what is causing the estop triggers.

If anyone can advise otherwise it would be appreciated.