Hi all, new member here. I know this is a fairly common type of issue but I haven’t found anything directly helpful, so hopefully I can give you all enough information to help me debug my problem.
Measuring voltage coming off the CRP800 for spindle speed seems wrong. I’m expecting 10V for 24K RPM, 7.5V for 18K RPM, 5V for 12K RPM. But actual numbers differ (and aren’t linear), 9.85V, 6.20V, 4.29V respectively.
I have been through every setting over and over again that I can find both in Mach4 and in the ESS plugin configuration. They are all correct and sensible. In order to get 18K RPM, I’m having to command the spindle to 21K+.
Are these all avid components? If so, they just helped me with a similar problem and I would encourage you to to reach out to tech support. Either way, based on the troubleshooting I just finished going through, I would guess the scaling is off in your VFD. I have recently upgraded to the EX controller with acorn so I can’t speak to how Mach/ESS works but my controller sends out a 0-10V signal to my VFD and, depending on it’s PROPER SETUP RELATIVE TO MY CONTROLLER/VFD/SPINDLE, it triggers the correct frequency/voltage.
I just went through resetting an reprogramming my VFD and there was a combination of parameters for input voltage and frequency, min and max frequency, rpm, etc… So your problem COULD be the setup in your VFD but, again, I was just given good advice to be VERY CAREFULL before punching buttons around in there…
FWIW, I fixed it today – it wasn’t a configuration issue at all, it was a signaling issue. I changed the wires running to the speed input of the VFD to a twisted pair, and all got better.