Hurco BMC 30 AP

Have a Yaskawa CIMR-MT III 11K spindle converter.

Are you getting the PG error on the spindle drive when you try to run it ?

No error with PG at spindle driver.

If you are not getting a PG error than I am doubtful of a bad encoder. When you give it a run command does it attempt to move the spindle? Typically bad encoders will move the spindle a little then error out with PG. You can kinda check the encoder with a multimeter, manually set voltage range, connect to 0V pin and one of the PC (A,B, or C) slowly rotate the spindle, that is more than likely a 1024ppr encoder so the difference between a high and a low on one set is going to be extremely small. Logic analyzer or oscope is a more effective tool for testing, when a digital multimeter is used and on autorange the sampling is often to slow to catch the high/low signal change when the encoder is moved to fast.

Try unplugging the encoder and attempt to run it. (should get a PG error)  If you dont get an error here, then there is something else blocking the spindle from attempting to run.

If the spindle will not move at all are you sure you have all the permissive met ?
Estop, ready ? and an analog speed input ?  Or forward or reverse run and a digital speed input ?

we proceeded as with the XYZ axis.
Encoder output from the driver connected to the Mesa card and checked in Linux whether the encoder value changes, everything works, see video.
We did the same with the spindle encoder, from the driver to the Mesa card, but the value in Linux remains fixed, no change.
5V encoder voltage is ok, wiring from encoder is ok.
We also compared the encoder of the XYZ axis with the encoder of the spindle.
The XYZ axes have a resolution of 2500ppr and the spindle encoder has 1024ppr.
We connected a digital multimeter to the XYZ encoder and you could measure a clean voltage change in the output signal.
We did the same on the spindle encoder, but no signal is received here.
If the spindle is at a standstill, I measure 3.76V, if I turn the spindle by hand, I measure 0V.
I got an oscilloscope the days, but no experience with it (yet).

We will also check the other wiring to and from mesa card ( analog, enable,….)

Thank you for your help.

Today we worked again at the Hurco.

We checked the Heidenhain encoder with an oscilloscope and it works.
Then we connected the encoder to the spindle driver, but unfortunately there is still no signal to the Mesa card.

The question is whether the spindle driver is ok; it definitely does not display an error message.
Is there a way to control the driver?

Then we selected the parameters for the spindle, something does not have to be right with the program, because the command S3000 already has 9V output voltage from the Mesa, but the 10V should only be present with the command S6000.

Summary of the day, the reference run is now working correctly, but the spindle is always turning
not yet.
We checked the cwiring and should be ok.

Do you have the spindle encoder connected to the spindle drive and the Mesa card?

If your not getting any errors on the drive that tells me that there is a permissive that's not allowing the drive to run. 

What is on the display when it's powered up? Does display change with run command? 

The LED's at the bottom are for spindle orient and winding change if yours is equipped. 

Do you have the

Estop chain closed?
Ready closed ? ( Don't have the manual in front of me)
You could close forward and one of the digital speed pins to force it to run. 

We connected the Heidenhain encoder 1: 1 to the original encoder.
First the encoder signal goes into the spindle driver and then from the spindle driver to the Mesa card.
The same signal flow is also with the axis driver, it works there.

When the machine is switched on, "Un-1" appears on the display.
Then I can switch through the parameters, see picture.
Which message should appear on the display if everything is ok?

The magnetic sensor for spindle orientation is originally connected.
If I turn the spindle by hand, a couple of LEDs on the spindle driver will flash.
We pulled the plug for the magnetic sensor on the spindle head to check what happened.
The leds stop flashing.
The signal from the magnetic sensor goes together with the spindle encoder to a common connector input on the spindle driver.

The wiring for the test is like this:

Yaskawa (Y) pin 3 (Analog NCOM) is connected to Mesa (M) TB5 pin 24 (AOUT5)
(Y) 4 GND -> (M) 23 GND
(M) 22 ENA5 (external 24V with relay for RUN)
(M) 21 ENA5- (external 0V)
(Y) 8 RUN relay from Signal (M) 22 -> (Y) 22 0V
(Y) 7 EMG -> (Y) 21 0V
(Y) 6 READY -> (Y) 20 0V
(Y) 12 SSC -> (Y) 28 0V

After a long back and forth, we looked again at the problem with the converter.It seems that there is an error, according to the display „overcurrent“.Through a Youtube video showing the same converter, we were able to find exactly the same error.A transistor module is broken, the circuit board doesn't look great either, someone here has already swapped parts.

Transistor