It's every single time.  If I use M3, spindle runs 100% reliably.  Or, if I use 
my XHC wireless mpg, that runs it fine too.

But on the Manual Control tab, there's a Spindle button with a CW button 
flanking it on the right and a CCW button on the left and +/- buttons 
underneath.  Hovering over the CW says "Spindle CW (F9)".  Clicking on that 
results in no effect from the spindle, and the VFD will not respond to M3, 
nothing can make it run.  It won't run g-code because spindle-at-speed will 
never become true and that's required to be true for G1 moves.  That will 
persist until the VFD power is cycled.  Rebooting LinuxCNC alone will have no 
effect and it's not necessary to reboot LinuxCNC along with cycling VFD power.

This is weird.  The VFD is controlled by a complied .c, which has a limited 
range of communication with the VFD, using a few regs.  LinuxCNC has to have 
sent something that breaks the VFD communication but I'm not sure what it could 
even send that would cause that failure that stores IN the VFD's states rather 
than a state of LinuxCNC's code.  It has to be on the VFD's registers because 
cycling VFD power is essential to recover, while restarting LinuxCNC is 
irrelevant to recovery.

Danny
---- Gene Heskett <ghesk...@shentel.net> wrote: 
> On Wednesday 29 June 2016 01:42:47 Danny Miller wrote:
> 
> > Well, I recreated it and confirmed cycling VFD power without rebooting
> > LinuxCNC makes the spindle run again.
> >
> > I looked into the HAL after the "Spindle CW" button breaks everything:
> > enable TRUE
> > is_alarm FALSE
> > is_at_speed FALSE
> > is_ready TRUE
> > is_running TRUE
> > reverse FALSE
> > run TRUE
> > watchdog_out TRUE
> >
> > compared with actually having it running with M3:
> > is_at_speed becomes TRUE (duh)
> > watchdog_out is FALSE
> >
> > Well, that's odd.  IIRC the watchdog is not getting data back from the
> > VFD in a timely fashion.  It is somehow locked up so that does seem
> > consistent with the situation.  But no idea how it's getting locked
> > up. The x200 VFD code sends a speed, dir, and run command and reads
> > back the coils.
> >
> How often?  This is sounding as it it has some sort of an internal 
> watchdog that is not getting "petted".  This function is normally done 
> by an addf in your .hal file as one of the last addf's, often next in 
> line after the addf that updates the outputs each servo cycle.  That way 
> the watchdog gets petted even if the rest of the system is sitting idle 
> waiting for its slow human to tell it what to do next. :)
> 
> For an older 5I25 card install, it looked like this in the .hal file:
> addf   hm2_5i25.0.pet_watchdog   servo-thread    # else he bites!
> 
> Do a "sudo dmesg -c" which will clear dmesgs cache, then start lcnc and 
> stop it. send the next "sudo dmesg >filename 2>&1" and post it here as 
> an insert of that filename.  I also find that printing a copy for future 
> reference is also quite handy as you go about configuring a working 
> system.
> 
> Point is, that if the setup has a watchdog, it should show up in that 
> dmesg listing, the whole thing is perhaps 60 lines in one of my machines 
> that uses a 5I25 card.  And its now part of the of the output write 
> function now done internal to the card when and output is written by the 
> driver. So it does not show up in my dmesg listing, and that line quoted 
> above now has a #in front of the addf.
> 
> Check the docs you have on this x200 vfd for any mention of a watchdog.  
> That should define how to "pet" it to keep it from barking.
> 
> OTOH, I do't have an x200 VFD, and its possible that it does not report 
> its presence when the program is run. In which case see the docs for the 
> x200.
> >
> > Danny
> >
> > On 6/16/2016 11:04 AM, dan...@austin.rr.com wrote:
> > > It's modbus, sorry forgot to mention that.
> > >
> > > What baffles me is the Spindle buttons on the panel, AFAIK, just map
> > > to the same spindle-run in the HAL that M3 goes to.  I remember
> > > looking at the HAL monitor on this weeks ago and IIRC it was
> > > "spindle run true, but spindle-isrunning false".  The spindle isn't
> > > moving at all.  I'll recheck the HAL and take proper notes.
> > >
> > > And like I say, the VFD won't run again even if you reboot LinuxCNC.
> > >  It will run if I cycle power on the VFD.  So, it's like it sent a
> > > toxic command to the VFD that changed a reg to something unusable. 
> > > I did make that x200_vfd.c from the WJ200_vfd.c VFD code, but it
> > > wasn't a major change, and it's simple, there's a run command,
> > > cw/ccw command (I made it so CCW just turns into CW), rpm command,
> > > and reads is-running-at-speed and an error bit.
> > >
> > > It don't see where it could deliver something to de-configure the
> > > VFD, nor why the Spindle panel buttons would do something different
> > > through the HAL than you'd get by MDI M3.
> > >
> > > Danny
> > >
> > > ---- andy pugh <bodge...@gmail.com> wrote:
> > >> On 16 June 2016 at 07:57, Danny Miller <dan...@austin.rr.com>
> > >> wrote: My MPG's "spindle" button works.
> > >>
> > >> On the default panel, ...  Clicking any of that doesn't make the
> > >> spindle go,
> > >>
> > >> It's not JUST that.  Once you click on any of that, the VFD *will
> > >> never run again* until power is cycled.
> > >
> > > How fascinating..
> > > Can we see your HAL files?
> > >
> > > Is the spindle controlled by Modbus or DC voltage? What hardware?
> >
> > ----------------------------------------------------------------------
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> 
> Cheers, Gene Heskett
> -- 
> "There are four boxes to be used in defense of liberty:
>  soap, ballot, jury, and ammo. Please use in that order."
> -Ed Howdershelt (Author)
> Genes Web page <http://geneslinuxbox.net:6309/gene>
> 
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