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Alright MAC!!!!!
I sir am UP and RUNNING!!
So what I ended up doing was like you said..... I grabbed the scope from work, came home and basically began tracing the PWM signal all the way back from...

You need these sir...

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You need these sir...

...

Mac,
Alright, Gonna go through the pins tomorrow.

That PWM board........ How do I talk to it? ethernet (RJ 45) from PC like a Port 2? And it has some relays to use? sounds good!

Hmmm..... may...

Ok,
Borrowed the scope from work....

I see PWM on P14 of the DB25 of the ESS...... Starts when I do M3 and stops when I M1

I DO NOT have PWM on G540 P9, P8



Sooo.... I can corner this...

MAC,

I have everything working in good fashion except spindle control through Mach3..

I have tested VFD with Spindle separately with manual control, works great.
I have tested communications...

Mac,
This sucks... I hope thats not the case kind sir.

Where and how many places in Mach3 do I need to tell G54 PWM to work?

G540 P7 ------ VFD GND
G540 P8 ------ VFD 5V OUT
G540 P9 ------...

Mac,
I adjust it with M3 commands.....

I have:

G540 P7 ------ VFD GND
G540 P8 ------ VFD 5V OUT
G540 P9 ------ VFD 5V IN
VFD GND (jumper) VFD FWD (Spindle pulley "Disabled" no DIR...

Hey Mac,
Ok, Did that.... Also Changed over PN-03 from (4) to (3) to tell VFD to expect a 0-5Vdc signal instead of the previous 0-10Vdc signal......

Ran an M3S20000 in Mach.....

Put my...

http://www.cnczone.com/forums/attachment.php?attachmentid=386472&stc=1

Hope the DWG is not to fuzzy..... But I think im understanding. Basically P5 connected to FWD will go on or off with mach3...

Mac,
Yessir..... thats the clunk of caca alright. I grew a grey hair just looking at it! lol.... is this yours as well?


DIY

Mac,
Oh Noooooooo!! It does not give me "FAULT" indication ..... Nice bright green light all the way..... man, I sure hope not.... wonder if I can read it directly fro G540 DB25 Pin14 to check for...

Sorry Mac,
Yea I tried the Pin5 to enable spindle DIR ...... I couldn't get the signal on the pin with Mach3 settings..
http://www.cnczone.com/forums/attachment.php?attachmentid=386356&stc=1


...

Hey Mac,
Good morning.. sorry I haven't been on in a couple days, things to do....

What I've done:

1. Ran my new IGUS Motion Cable through the flex chain, but have not yet made any...

Mac,
So here's what I have now.......
http://www.cnczone.com/forums/attachment.php?attachmentid=386354&stc=1
With MDI M3S24000 Mach3 DRO Jumps from "0" straight to 23000 in less than a second then...

Al,
Isnt the G540 GND Pin7 Isolated from G540 GND Pin 12 ? your Dwg suggests they are COM with the VFD DCM
http://www.cnczone.com/forums/attachment.php?attachmentid=386348&stc=1
Here is my...

Hey Mac,
Good morning.. sorry I haven't been on in a couple days, things to do....

What I've done:

1. Ran my new IGUS Motion Cable through the flex chain, but have not yet made any...

Mac, Please see attached doc I created of my pinouts and how its correlated in MACH. Simplifies the flow a bit to put things into perspective.... feel free to share with other dum dums like me,...

Mac,
Well the good news is I no longer get a ESTOP or Error message in MACH3 when I turn the spindle on...... Not sure if I can quite call it progress at this point because the spindle still won't...

PN 04 set to #2

DIY

Mac,
Thx for looking at that.... As clearly I'm a bit confused with it, lol. I will be playing with it all weekend, can't wait to get cracking on it!!

My BOB I'm using is the ess, it interfaces...

http://www.cnczone.com/forums/attachment.php?attachmentid=385560&stc=1http://www.cnczone.com/forums/attachment.php?attachmentid=385562&stc=1http://www.cnczone.com/forums/attachment.php?attachmentid=38...

Mac,
Yeah I've read a lot about the issues of grounding the spindle shell on here so I went ahead and took the liberty of ordering for pin connectors at the same time I ordered the motion cable...

Yes sir, I can... Don't laugh at my mess!?

VFD:

http://www.cnczone.com/forums/attachment.php?attachmentid=385482&stc=1


G540:...

Cool......Done, ordered. Thank you sir!

Ok, so I haven't played with probing G540 terminal block to get PWM signal yet.... Im still not confident about the wiring between the two, dont want to fry...

Good Stuff!!!
Thanks MAC.... More homework!!! lol... I have tons of phone cable at home... gonna clean up all this EMI crapola as soon as I get home today. Another night out in the mancave!!
...

Hi Gerry,
Thanks for response on this! No, I am not using shielded cable. I will be tonight though as I will stop at lowes on way home from work today to swap that out... I am currently using...

Hi Mac,
Thanks for looking at this..... if your ever in FL ill buy yea a beer one day!! lol...

My VFD: (Remember, works just as it should manually)

PN03 - 4 (External 0-10V signal)
PN04 - 2...

Awesome, thanks for reply!
Noise from my vfd? Hmmmm.... This seems plausible for sure. My 3 wires from vfd to G540 (pins 7,8&9) are 14 awg stranded hookup wire... I twisted them together rather...

Hello,
I for the life of me cannot get my spindle to do a dang thing with Mach3.... everytime i go to turn on the spindle in Mach it triggers estop and gives message saying "PWM bumped to minimum...

I also have 6040, 800kw (HUANYANG GDZ-65-800c) / HY01D523B 1.5kw Inverter

Driver:
GECKO G540

COM:
ESS (Ethernet Smooth Stepper)

GUI:
MACH 3