Need some debug help isolating a spindle problem

Particulars on my set up at the end. My machine crashed and I’m way behind on a deadline. Thought I’d throw some questions out there in the hope of getting to the bottom of this quickly. Running 2.9.2 QT Dragon HD.

Everything has been running well (software at least) for the past 6 Mo. Today I was making a cut similar to other work I’ve been doing and the spindle stopped spinning half way through the job.  QT showed the error “hm2/hm2_5125.0: Smart serial card hm2_5i25.0.7176.0.0 remote error = (27) Over Current” I assumed this involved my Modbus connection to my Hitachi VFD and there was a VFD complaint re: the spindle. I power reset everything and restarted, hoping to get lucky. 

After restart and Homing, in QT Dragon MDI I issued an s5000 which should start the spindle, right? Nothing.

I pulled up Halshow for the wj200 driver for the Hitachi VFD. The Modbus watchdog is ticking, the heat sink temp seems to update, and it shows ready and enabled. s5000 does not show the commanded-frequency (Driver setting) to the VFD however.

When I unlink commanded-frequency and attempt to set with halshow, I lose the Modbus watchdog. With s5000 set, the VFD just shows 000 on its display. The fluke in AC mode seems to agree there is nothing going to the spindle. 

So. Everything else on the machine is healthy/ power is good. The VFD seems ok (watchdog, sets ready when machine enabled, HS temp). I’m prepared (sorta) to believe that the spindle died for some random reason, BUT I can’t get past the fact that I don’t seem to be able to command the VFD to turn the spindle on.

Maybe I’m going at this wrong? I’m avoiding trying to command the VFD from its front panel because the process is error prone (for me at least) and I wouldn’t know if the spindle was busted or I just screwed up the VFD commands.

Thanks for any suggestions. I’ll need to start doing things the old fashioned way pretty quick I I don’t get this thing running.

Machine summary: Gantry style router. Clear path servos. Quad core I7 with 5i25/7i76. Hitachi WJ200 VFD. 3hp Chinese WC spindle with ATC. 

“hm2/hm2_5125.0: Smart serial card hm2_5i25.0.7176.0.0 remote error = (27) Over Current”

Means there is an an issue (most likely a short) on one of the 7I76 field outputs
 

Thanks Peter. Was my 1st thought, but the with the spindle being the only thing not working, and all the VFD ctrl coming from the Modbus, it wasn’t obvious how this could be a culprit. I’d guessed it was some knock on effect fm when the spindle 1st quit.

FWIW, that error message only showed at the 1st event. After restarting, nothing complains.

Maybe a wiring issue?

Transient electrical problem that came from or damaged the VFD?

Does the VFD have any connections to the 7I76 or is it entirely controlled by MODBUS?
 

I’ll dig through it for a bit this morning. It’s been a year since I did serious work on the machine; have to see if I’m forgetting something. I’m pretty sure it’s Modbus only. Machine was rewired a little over a year ago; it’s pretty clean and fresh if I do say so myself

VFD is not showing faults. I guess I’ll try running the spindle directly from the VFD panel. I hate that UI.