I think its fixed now. after being on the phone for 4 straights days and checking every possible problem including replacing the encoder this morning. I finally said screw it and called the people we ordered the machine from to order a inverter, well I forgot the number and had there service guys number so I called him.
he came up with a really bizzare answer for me to check so I said ok hang on the phone as I had a screw driver in my hand.
I had to open the inverter case and 2 wires were keeping me from opening it fully. so he told me to call him back, as he was in the middle of something.
I undid the wires opened the case and noticed that one of the blue thick nickle sized MOV parts vibrated. I touched it and it fell to the floor.
he had told me to check this and see if they were connected ,loose or even there on the bottom of the control box. Apparently this has happened a few times in the past with the older sweo drives (1995 model).
went to the neighbors shop and got his solder sucker and then he resoldered it back on, the whole process took about 20 mins came back to the shop hooked it all up and ran a bunch of parts for 3 hours at 10000 rpms ( just for the heck of it and had not had one error).
we have gone through the entire machine, every possible senerio was gone through. I would get a "oc" Lower case error on the inverter once or twice then yesterday I got it about 12 times including a "dclo" (lowercase) error which I got for the first time since friday night. Lower case errors on baldor drives according to baldor techs mean "uncertain errors"
I talked to fadal and baldor both. there were all helpful , Fadal ( Gary) even called me back a few times to try this or that. Gary at Fadal tech.. support is a drive whiz. and very maticulous (sp) and will talk you through everything step by step of the way.
As I am typing this the machine is running at 10k, with my luck it will probally die as soon as I hit the "post Quick Reply button" this is however the longest it has run with no dramatic spindle speed changes on the rpm led on the drive ( its varying about +- 1 rpm, before it was varying about +- 20-30 rpm )
I got a few drive tests for the SWEO drives and if someone thinks It would help someone else in the future it I will put it together. it is extreamly easy to disconnect the drive from the control and run it off a 9volt battery , doesnt take any special tools or pins either. The machine control doesn't even have to be turned on, just the main power. what this does is let you know if its a drive issue ( meaning inverter , motor and encoder) or a control issue ie controller card or wiring in the control circuits.
On the bright side if this continues to work my cigarette intake will be about 2 packs less a day
