Spindle will not stay running

Hello,
I am scratching my head for days trying to solve a spindle problem. I have setup 2 other mesa boards and everything was fine.
When I attempt to start the spindle (M3 S12000) or click forward in the GUI the spindle starts then stops about 1 second later.
I did have On_Abort_Command setup and it called the abort which is the only thing I can get it to log. If I change the VFD to manual control the spindle works fine. Testing the 10V spindle out seems to be fine for the 1 second then drops to 0v. The machine almost always goes to "Machine Off".
The only differences to the other machines is they have dual Y and the size of the VFD.
I ran pncconf to setup a blank 3 axis limited machine for the 7i96s, axis work fine but spindle still causes the machine to reset.
My hal and ini are a mess from testing once I clean them up a bit I can upload them if needed, they are out of the box from the pncconf.
Motion seems to be fine, limits are working. I went through the .INI and .HAL line by line comparing all spindle items and found them to be identical. But of course the others work and this one faults.

Is Electromagnetic noise from the VFD ruled out?

I never thought to check that. I do have a filter on the VFD power. I will move it and see if that changes the problem.

Thanks for the idea. When I ran a few simple tests with no effect. I'm not sure how to test for emi. I expect if there was some my test would have had a reaction change but nothing changed. I moved the VFD as far away as I could and added a grounded makeshift shield.

if I change the VFD to manual control the spindle works fine. Testing the 10V spindle out seems to be fine for the 1 second then drops to 0v. The machine almost always goes to "Machine Off".

The question then would be why you get to the machine off state. (this will certainly turn off the spindle)

If you start LinuxCNC from the command line, are any errors displayed?
 

Hello PCW,
Thanks for the reply. Below is the output from the command line run. There is another error that sometimes appears but not in this run.
AT-SPI: Could not obtain desktop path or name.
I added manual events with ***************** this was not log captured

larryp@2x4cnc:~$ linuxcnc
LINUXCNC - 2.9.4
Machine configuration directory is '/home/larryp/linuxcnc/configs/CNC2x4'
Machine configuration file is 'CNC2x4.ini'
Starting LinuxCNC...
linuxcnc TPMOD=tpmod HOMEMOD=homemod EMCMOT=motmod
iopl() failed: Operation not permitted
cannot gain I/O privileges - forgot 'sudo make setuid' or using secure boot? -parallel port access is not allowed
Note: Using POSIX realtime
Found file(REL): ./CNC2x4.hal
hm2: loading Mesa HostMot2 driver version 0.15
hm2_eth: loading Mesa AnyIO HostMot2 ethernet driver version 0.2
hm2_eth: 10.10.10.10: INFO: Hardware address (MAC): 00:60:1b:16:8a:55
hm2_eth: discovered 7I96S
hm2/hm2_7i96s.0: Low Level init 0.15
hm2/hm2_7i96s.0: Smart Serial Firmware Version 43
hm2/hm2_7i96s.0: 51 I/O Pins used:
hm2/hm2_7i96s.0: IO Pin 000 (TB3-01): InM Input Module #0, pin in0 (Input)
hm2/hm2_7i96s.0: IO Pin 001 (TB3-02): InM Input Module #0, pin in1 (Input)
hm2/hm2_7i96s.0: IO Pin 002 (TB3-03): InM Input Module #0, pin in2 (Input)
hm2/hm2_7i96s.0: IO Pin 003 (TB3-04): InM Input Module #0, pin in3 (Input)
hm2/hm2_7i96s.0: IO Pin 004 (TB3-05): InM Input Module #0, pin in4 (Input)
hm2/hm2_7i96s.0: IO Pin 005 (TB3-06): InM Input Module #0, pin in5 (Input)
hm2/hm2_7i96s.0: IO Pin 006 (TB3-07): InM Input Module #0, pin in6 (Input)
hm2/hm2_7i96s.0: IO Pin 007 (TB3-08): InM Input Module #0, pin in7 (Input)
hm2/hm2_7i96s.0: IO Pin 008 (TB3-09): InM Input Module #0, pin in8 (Input)
hm2/hm2_7i96s.0: IO Pin 009 (TB3-10): InM Input Module #0, pin in9 (Input)
hm2/hm2_7i96s.0: IO Pin 010 (TB3-11): InM Input Module #0, pin in10 (Input)
hm2/hm2_7i96s.0: IO Pin 011 (TB3-13/TB3-14): SSR #0, pin Out-00 (Output)
hm2/hm2_7i96s.0: IO Pin 012 (TB3-15/TB3-16): SSR #0, pin Out-01 (Output)
hm2/hm2_7i96s.0: IO Pin 013 (TB3-17/TB3-18): SSR #0, pin Out-02 (Output)
hm2/hm2_7i96s.0: IO Pin 014 (TB3-19/TB3-20): SSR #0, pin Out-03 (Output)
hm2/hm2_7i96s.0: IO Pin 015 (TB3-21/TB3-22): OutM Output Module #0, pin Out-04 (Output)
hm2/hm2_7i96s.0: IO Pin 016 (TB3-23/TB3-24): OutM Output Module #0, pin Out-05 (Output)
hm2/hm2_7i96s.0: IO Pin 017 (TB1-02/TB1-03): StepGen #0, pin Step (Output)
hm2/hm2_7i96s.0: IO Pin 018 (TB1-04/TB1-05): StepGen #0, pin Direction (Output)
hm2/hm2_7i96s.0: IO Pin 019 (TB1-08/TB1-09): StepGen #1, pin Step (Output)
hm2/hm2_7i96s.0: IO Pin 020 (TB1-10/TB1-11): StepGen #1, pin Direction (Output)
hm2/hm2_7i96s.0: IO Pin 021 (TB1-14/TB1-15): StepGen #2, pin Step (Output)
hm2/hm2_7i96s.0: IO Pin 022 (TB1-16/TB1-17): StepGen #2, pin Direction (Output)
hm2/hm2_7i96s.0: IO Pin 023 (TB1-20/TB1-21): StepGen #3, pin Step (Output)
hm2/hm2_7i96s.0: IO Pin 024 (TB1-22-TB1-23): StepGen #3, pin Direction (Output)
hm2/hm2_7i96s.0: IO Pin 025 (TB2-02/TB2-03): StepGen #4, pin Step (Output)
hm2/hm2_7i96s.0: IO Pin 026 (TB2-04/TB2-05): StepGen #4, pin Direction (Output)
hm2/hm2_7i96s.0: IO Pin 027 (TB2-07/TB2-08): Encoder #0, pin A (Input)
hm2/hm2_7i96s.0: IO Pin 028 (TB2-10/TB2-11): Encoder #0, pin B (Input)
hm2/hm2_7i96s.0: IO Pin 029 (TB2-13/TB2-14): Encoder #0, pin Index (Input)
hm2/hm2_7i96s.0: IO Pin 030 (TB2-16/TB2-17): IOPort
hm2/hm2_7i96s.0: IO Pin 031 (TB2-18/TB2-19): IOPort
hm2/hm2_7i96s.0: IO Pin 032 (internal): IOPort
hm2/hm2_7i96s.0: IO Pin 033 (internal): SSR #0, pin AC Ref (internal) (Output)
hm2/hm2_7i96s.0: IO Pin 034 (P1-01/DB25-01): IOPort
hm2/hm2_7i96s.0: IO Pin 035 (P1-02/DB25-14): IOPort
hm2/hm2_7i96s.0: IO Pin 036 (P1-03/DB25-02): IOPort
hm2/hm2_7i96s.0: IO Pin 037 (P1-04/DB25-15): IOPort
hm2/hm2_7i96s.0: IO Pin 038 (P1-05/DB25-03): IOPort
hm2/hm2_7i96s.0: IO Pin 039 (P1-06/DB25-16): IOPort
hm2/hm2_7i96s.0: IO Pin 040 (P1-07/DB25-04): IOPort
hm2/hm2_7i96s.0: IO Pin 041 (P1-08/DB25-17): IOPort
hm2/hm2_7i96s.0: IO Pin 042 (P1-09/DB25-05): IOPort
hm2/hm2_7i96s.0: IO Pin 043 (P1-11/DB25-06): IOPort
hm2/hm2_7i96s.0: IO Pin 044 (P1-13/DB25-07): IOPort
hm2/hm2_7i96s.0: IO Pin 045 (P1-15/DB25-08): IOPort
hm2/hm2_7i96s.0: IO Pin 046 (P1-17/DB25-09): IOPort
hm2/hm2_7i96s.0: IO Pin 047 (P1-19/DB25-10): IOPort
hm2/hm2_7i96s.0: IO Pin 048 (P1-21/DB25-11): IOPort
hm2/hm2_7i96s.0: IO Pin 049 (P1-23/DB25-12): IOPort
hm2/hm2_7i96s.0: IO Pin 050 (P1-25/DB25-13): IOPort
hm2/hm2_7i96s.0: registered
Found file(REL): ./custom.hal
Found file(REL): ./xboxctrl.hal
note: name is 'Microsoft X-Box 360 pad'
note: name is 'Microsoft X-Box 360 pad'
**************** This is the end of startup before Machine On was pressed, no logged events from Pressing Machine on.
**************** MDI: M3 S9000 - ran about 1 second
task: main loop took 0.124348 seconds
task: main loop took 0.100006 seconds
**************** MDI: M3 S14000 - ran about 1 second - note sometimes it runs for 3-5 seconds but never gets spindle to speed
task: main loop took 0.124488 seconds

**************** EXIT button pressed
qt.qpa.xcb: QXcbConnection: XCB error: 3 (BadWindow), sequence: 31380, resource id: 8630017, major code: 40 (TranslateCoords), minor code: 0
Shutting down and cleaning up LinuxCNC...
Running HAL shutdown script
task: 19007 cycles, min=0.000013, max=0.124488, avg=0.010070, 3 latency excursions (> 10x expected cycle time of 0.010000s)
hm2_eth: in hm2_eth_reset
hm2_eth: HostMot2 ethernet driver unloaded
hm2: unloading
iopl() failed: Operation not permitted
cannot gain I/O privileges - forgot 'sudo make setuid' or using secure boot? -parallel port access is not allowed
Note: Using POSIX realtime

Nothing too obvious

I would try running without the XBOX controller
USB devices are notoriously sensitive to noise.
 

It had no effect removing the xbox.hal and disconnecting the controller.
Something I noticed this time is I changed to qtdragon (from qtdragon_hd) so I could see the terminal window behind. In that change I noticed the "At Speed" indicator beside the spindle controls turns green when I enter the M3 S9000 and when the motor stops the indicator flashes.
The other not so obvious item is the machine 95% of the time switches to "Machine Off" but not 100% of the time.
I also noticed the secure boot was enabled, I thought I had disabled that. It is now disabled in bios.

Had an idea, dangerous I know!
I put a buck converter on the 24VDC supply to get me 10VDC for a ref voltage for the spindle output. Tested with the buck converter and of course had the same problem but it allowed for another test. Note the spindle out was at 5V then 0V when the spindle stopped.

I powered off the breaker for the VFD and put my meter on the Spindle Out/Gnd. The M3 S9000 (5V) held with no reset. I tried a few different speeds and all worked. It is some type of EMI problem.

Any suggestions on how to resolve this? I have a EMI filter on the VFD. I tried moving the VFD further away from the 7i96s and no effect.

Switching to machine-off indicates LinuxCNC sensed something
and changed operating mode.

The question is what did it sense.

Can you post you hal/ini files?