Spindle not acheiving set speed before spindle fault

[Fueler1]

This happens from time to time and haven't been able to outsmart it.
Spindle rpm starts as the z moves down toward the part. If it does not reach X rpm it faults out.
It also seems slow to reach x rpm
In the past a faulty spindle encoder was to blame. Not this time.
It always seems a bit backwards to me. Would achieving set rpm before moving the Z be more logical?
FWIW I can manually speed up or slow down the spindle rpm without issue.
Thoughts?
File attached

.

report_0008DC111213-0416151269_2025-05-24_08-39-33.zip

(1.01 MiB) Downloaded 2 times

[cncsnw]

When the Centroid control says "9030 SPINDLE FAULT!", what fault code appears on the LED display of your spindle drive?

[Fueler1]

Sorry for delay. Life and health got in the way.
Error message is Fault, ocA. oc at accel

[cncsnw]

I suspect there is still an issue with the spindle encoder, or the spindle encoder cabling, or the EMC-PG01L board in the Delta C2000 drive.

You could test that by changing Pr. 00-11 in the Delta drive from 3 to 0, so that the drive runs the motor in an open-loop V/f mode instead of the closed-loop "FOCPG" mode. In V/f mode, the spindle drive is not dependent on the encoder feedback.

To run jobs on the machine with the drive in V/f mode, you would have to rename, delete, or edit your M6 macro file (mfunc6.mac). Your existing M6 macro file always tries to orient the spindle before prompting you to change tools. If you rename or delete that file, then CNC12 will just stop the spindle (without orientation) and prompt you to change tools.

To your question of whether axis movement (such as Z down) should be allowed to begin before the spindle is up to speed: normally, it is.

If you want to ensure that the machine does not try to cut before the spindle is up to speed, your best bet is to change:
Parameter 78 from 1 to 5
Parameter 149 from 1.0 to 0.9
That will make CNC12 pause any feedrate movements if the measured spindle speed (according to the encoder) is less than 90% of the programmed spindle speed. Rapid moves (including Z down after a tool change) will still be allowed to proceed, even as the spindle is ramping up.

If you do not even want the machine to do rapid moves until the spindle has had time to start up, then you could just put a G4 dwell after each M3 spindle start. Intercon will do that automatically using its "Spindle/Coolant Delay" parameter (P102). If you are using another CAD/CAM system you could either get that CAD/CAM vendor to modify your postprocessor to include a dwell time; or you could edit your M3 macro (mfunc3.mac) to include, for example, "G4 P3.0" or "G4 P#9102" on a line after "M91/4".

[Fueler1]

I have fussed with that spindle encoder far too many times.
I have changed it out at least twice and beefed up suspect portions of it. No real help.
However, I have come to believe that the issue is a mechanical one. The head on this bed mill has always been incredibly noisy.
It generates a knock, rattle or thump for lack of better terms.
I have replaced the bearings in the upper section that holds the belts along with new belts. Replaced the bearings in the spindle also.
Knock is still there so I assume that it has to be in the gear section.
My thinking is that the knock rattles everything just enough to upset the spindle encoder particularly at higher rpms.

Will experiment with your suggestions.