Quote Originally Posted by dachopper View Post
The only original parts are UC400ETH, UCCNC + PC software and hardware, Spindle, motors + wiring..

More clues, just had fault number 3 for today on video, I had everything running, but no drill bit in the spindle, ( All electrics on and running, spindle was turning but with no BIT. This time the X axis jammed during a left to right travel movement. just after reaching retract height, under no load. AM882 stall detect SHOULD have picked up this stall, it was at 450rpm, but it didn't........ some kind of electrical interference?

Did another RUN everything turned on again, but this time the spindle freewheeling ( inverter powered but no power to spindle ).....18 minutes later, no fault

Ok - I've now noticed that the X axis jam that happened in mid air snapped the coupling in half.

Just ordered some different spindle shielded cable - siemens proflex EMV

I do have the spindle running in the same 50mm cable carrier as the X / Y motors... would this normally be ok? I don't think I've seen a DIY machine that doesn't run this setup yet?
Normally it is not an issue to run the spindle and stepper cables in the same cable carrier. I have done that and never ever could relate any problems to that.

Right now I think you are a bit upset and inconsistent/badly structured in your efforts to finding out what's wrong. I think it would be a good idea if you could cool down a little, accept the fact that you have many problems and try to solve them one by one. I understand that you are upset and emotional but it does not help in fault finding. Remove the spindle from the loop by completely disconnecting it from the mains. At this moment milling air is perfectly fine. No need for a spindle at all. Try to solve all the other issues first since your machine is useless as it is anyway. Describe your machine, post a few pics of major parts and technical specs and settings. Answer questions instead of asking loads of new ones in a non-structured way, because at least I have problems with understanding your actual issues, there seems to be far too many and probably not related to each other, but I don't know.

The snapped coupler may be because you are using the type which is frequently sold on eBay as "flexible coupler" and basically is just a joke and they can snap and also cause other issues, but since you don't post any pictures or video it is difficult to say what can be the problem with each issue.