I was trying to find things in changelog, but there is a lot of builds missing.

...

April 8/2010
Release 3.042.039
-- Added the license name to the top of the screen
-- Added the ability to read a license file with extra data after the .dat
-- Driver update for debounce
-- Spindle reverse fixed if in "pulley reverse"


April 10/2010
-- Redid the driver version number to be 550
-- Made the license name show in Sim mode


//Many updates added and debugged to get to this stage...
May 2/2011
3.043.036
-- Run Script added and lots of work to get it to shut down when an Estop Stop or like event happens
-- Lots opf VB tools added for managing scripts (Check VB doc for added calls)
-- Bug fix for Spindle speed getting set by an external device (P POrt)
-- Threading Driver update for the P POrt
-- #Expand added to VB for source control

...

Ok just loaded 022 and start Mach (Used SS rather than ESS as its what I have here at home on the desk) Press spindle button on screen and it starts flashing and message says PWM bumped to min, just as expected. Not sure where your problem could be but doesnt seem like its directly related to Mach unless its an ESS issue. Do you have the spindle set correctly in ESS config
Hood

Sorry just realised its not you withthe ESS, regardless it seems to work fine for me as I just tried with the driver loaded.
Hood

Well, I just installed current dev build (66) and problem went away. So I guess I'm OK from this perspective.
Btw, did you completely uninstall 62 before you installed 22? Just curious.

Anyway, now the other questions. Because it looks like you really understand, what are you talking about, can you please explain to me, how to properly tune spindle?
I already mentioned that in my first post. I need to set up at least ramps properly, but I have no clue, how to map steps, velocity and acceleration on the tunning tab on my setup.
My spindle has 24000rpm, ramp 3 secs up, 3 sec down.

Thanks!

You can set a delay from Config menu the Ports and Pins then finally Spindle Setup.
As for what you need to actually set steps etc to afraid I dont know as I have never used the G540 but should be in their manual I would think.
Hood

I do not think my question is relevant to G540. I'm trying to figure out:

1) What "Steps per" means, if you have enabled PWM control of the spindle (not step/dir).
2) Same for "Velocity in in-mm per minute". I want to set velocity in RPM.
3) Same for "Acceleration in-mm/sec/sec". I want to set acceleration in RPM/sec.

I use base frequency 50 (I assume Hz).
I want to set ramps for acceleration and deceleration, max RPM etc.

Edit: Ok, I understand, that velocity does not matter. I will just get 0-10V anyway. But ramps are important.

So, I have finally everything running with one of my better VFDs (PowerFlex 70). Huanyang will go collect some dust. Once I figured out wiring, everything was relatively easy.
PowerFlex has also digital inputs with relays configurable as start/stop/fwd/reverse etc ... so I could hook up G540 digital output directly to PowerFlex without additional circuitry.

What I learned:
1) Original G540 XML file (provided by Gecko) for Mach3 is wrong. Pin dedicated to spindle has to have step bit 1, not 0. Once I figured that out, it all worked in build 22 and in build 66. So Hood was right. I saw different results, because I had these 2 builds in different folders with different XML files. One was fixed, other was not.
2) Motor tuning for "Spindle axis" does not do anything for PWM driven spindle. I just looked that up in manual. Maximum speed (in RPM) is derived from your pulley selection, ramping up/down is done in VFD.
3) It is wort to use shielded cables. I do not any interference between from spindle PWM, VFD or steppers anywhere.

Hood, thanks for help.

Good you got it going oh and to answer your question that I missed, I just install over the top of whatever version of Mach I have currently installed.
Hood

vorrei segnalare l'ottimo software free per PowerFlex
www.aig.altervista.org