Why did my spindle shut off?

While performing the detail pass of a 2-stage cut with a 1/32" bit, my DWP611 powered down at around 80% complete, IN THE MIDDLE OF THE CUT!!! of course this caused my bit to snap.

this was the first time that this has happened. I was standing right next to my machine when it happened. I started looking at the machine to figure out exactly what was going on and about 2-3 seconds later, SNAP!

the weird thing is the machine continued to process the Gcode, just without a cutter or the spindle powered up.

I stopped the carve and reset the tool.

I do not know Why this would have happened

directly after i entered the command console and entered M3 S14000 and the 611 powered right up. M5 and powered down.

I flipped my rocker switch to the ON Position, the 611 powered up. flipped it back to the logic position,611 powered down and its ready for the next carve.

this is like the 30th carve that i have performed but the first time that this specific glitch has happened

i am running the spindle off of a solid state relay.

I figured that i could go in and check the "Current"Gcode file to see if it had a M5 located in the wrong location causing my spindle to power down, but Easel had to Re-Generate the file, so of course this new file may not be the same as the old one that the machine was just running.

Is there any way to see the ACTUAL Gcode that is being sent to the Arduino?

It is only logical to be able to see the Current Gcode path being sent, and not having to re-generate the code each time. if i am correct even the generated Gcode under the machine tab may not be the exact Gcode path sent to the arduino. My logic behind this is in the machine tab the Gcode can be Generated and Exported but not processed immediately by the machine. To process immediately by the machine using Easel, the machine tab must be closed out and the Carve tab needs to be pushed which now generates the Gcode path that will be sent to the Arduino. There is no guarantee that these two paths will be exactly identical.

So with this said, here is my problem, is there something that i am missing that will allow me to see the CURRENT Gcode file being translated instead of having to Regenerate the Code each time i want to see it? because it may not be the same that was just sent. I have had some paths different than others on the exact same picture, i have noticed that the tool paths are not always identical each time that they are calculated, thus resulting in different Gcode patterns.

I have even had an issue with 2-stage cut where the Detail Pass did not get everything left behind, by my assessment it looked as if the Rough Pass actually missed a few areas. But this only happened during one cutting board not both of them, so that has me a little lost as well.

in this situation, IF i could go back and see the ACTUAL Gcode that was sent to the Arduino, then maybe i could find the command that powered down my 611. There is no other reason for the 611 to have powered down and if there is, somebody please educate me bc this has me dumbfounded. AND i know one thing, I Do Not Want This To Happen Again. this hiccup cost me a $20 bit and i have no way to find out exactly why it happened.

Any Help would be greatly appreciated.

I have had this happen as well. I don’t know if this was the same issue as you but I had the dewalt on way too high, speed 4-5 for all of my carves. Ended up destroying the ‘brushes’ in the dewalt. I can’t remember the posts but there are fixes as well.

my spindle still works, it just powered down for no apparent reason.

This 611 has maybe 10-15 hours on it TOTAL ( and always on low settings, this machine has not even seen anything over 50% speed). the Brushes are still good everything still works like normal. this leads me to suspect that the Gcode was the culprit, but I have no way to verify. With nothing else wrong and no other way to verify, i can only speculate that the Gcode was incorrect with my issue, unless somebody can give me a better explanation

What is the make and part number for the SSR you are using?

I don’t know about Easel, but UGCS shows the g-code in real time as it is sent to the device.

LarryM, this is it


Soon I will try UGS. Right now I am trying to learn easel, but I am generating and saving my Gcode paths. My abilities with any Cad will need to increase before I can really do much more. I have only had my machine up and running since the first of the year and have not been able to make it in the shop as much as I would like.

Are you doing this inside Easel? Can you export the g-code from Easel and edit it before you run the job to search for M5 commands?

Yes, I am using Easel.

After the cutter snapped, I went into the advanced settings and “Exported Gcode” I checked that Gcode file and this file was fine, but I do not know of a way to check the actual code that was sent when the cutter broke. This is something that I would like to have changed so that I can preview the current Gcode that the machine is processing.

Same thing happens when trying to export a 2-stage cut. I have to generate once for the roughing and a second time for the detail pass. This seems redundant making the system process the same command over and over.

Since I do not like this current situation here is my current plan.

I am using Easel to generate my Gcode paths by exporting the paths under the advanced settings. The code is generated in another window. Where I select all and copy.

I open a fresh file in Numbers (Apples version of Excel) and paste the Gcode file. This breaks the file down line by line, where I can review and edit (if I like).

Now I save this Numbers File, where I can access it later if I want.

In the future I do not have to regenerate the Gcode anymore, after I verify the first run. I can copy the Gcode from the Numbers/Excel file and paste it into a version of a Gcode sender.

I am currently attempting to carve multiple cutting boards. I have had issues where easel has locked up while trying to process and carve too much on one cutting board. I decided to break down the pattern into several sections. The Numbers/Excel file allows me to set up different Sheets for different sections of the cutting board. A Gcode path is generated and then saved in its designated sheet. This allows me to only change certain aspects of the sign, such as names, by only needing to generate code for that specific name/lettering.

Now for my next cutting board, I open up the Numbers/Excel file and copy and paste only the Gcode paths needed for that specific cutting board. This will then give me a verified program that I know that will work the next time.

Be sure to also save the setup information such as bit size and type, feed rates etc. so that down the road you can still use the files.

Thanks LarryM,
Will do, bit size is saved as part of my file name. Feed rate is saved in the Gcode and by doing a quick search and replace I can use the Numbers/Excel to quickly alter the feed rate throughout the entire file.

Depth of cut is the only variable that will be difficult to quickly change, but I use a conservative number here and it is directly related to the size of the cutter. So adjusting the feed rate and the speed of the cutter, imo, should be all that I need to really change in the future depending on the hardness of material being used.

Anything else I should be concerned about by using this method?

I think you should be able to get this to work for you, but it seems very inconvenient. It might be better use of your time to find a tool chain that you can trust. That would make changes a lot faster with less manual intervention.

I’m still trying to figure out what happened to make your router stop. It may not be the G-code at all, but so far I haven’t thought of a situation that would fit your experience.

Thanks LarryM. This makes no sense to me. I am glad that I was standing next to my machine and witnessed it first hand. Even though I can not exactly explain what went wrong at least I know what happened when it went wrong. Instead of coming back to my carve later only to find a broken bit and not everything carved.

Kind of a double edge sword though since I can not explain why it happened. (But at least I know what happened). :slightly_smiling_face: Lol

Spooky things happen with electronics. If I had to take a guess on this one, my first shot at it would be the speed controller on the router. Second guess would be the solid state relay.

If it were in my shop I would set up some monitoring equipment to see if I could catch it in the act.

Not sure if this was your issue, but I have seen examples of my Dewalt 611 stopping unexpectedly if I did not get the switch pressed to ON completely. The plastic dust cover for the switch can sometimes make it difficult to be sure the switch is completely rocked to the on position. There is a middle range where the router will turn on, but the switch is not fully engaged. A little vibration can cause the switch to flip back to OFF.


I just can’t imagine letting the Arduino trigger my router on and off, let alone the faux speed control with a spindle. You can simply plug your router in to an outlet and turn it on and off with its built in switch.

THere have been reports of routers turning on for no reason as well. (static electricity, voltage spke, who knows).

Well, honestly I hijacked the speed controller on the router. Yanked it out completely. I replaced it with the components from the harbor freight spindle control. I believe it was Angus who recently posted how he wired up his PID and bypassed the speed control. Well this is similar to what I did but I yanked the entire module out, since it is not being used now. So then what is the point of the extra weight. And yes I have lost my ability to use my LEDs but I ran a set of wires into my 611 to power them, I just have not hooked them up. So for now, no lights at all. But my shop is well lit so I really haven’t noticed that to be an issue.

I set my control box up so that when I have the funds, a PID upgrade will be very simple.

My machine has seen around 30 or so carves now. Never once has it decided to turn off in the middle of a cut. My spindle control has been flawless up until this point. Absolutely no glitches since I powered it up and figured out how to change the spindle speed by selecting the Other Spindle instead of the Dewalt.

I was fortunate that I was standing there to see it happen even though I yet know the exact cause. I will be adding video surveillance to my system very soon I just jave to purchase the cameras. I already have a home surveillance system, a Swann from Lowes. It is capable of 8 cameras and I am only using 4 need total of 6 to cover my entire property leaving two inputs left over. These will be for monitoring inside my shop for such this situation. :nerd_face: Just gotta get more $$$ first if you know what I mean. I tried not to overspend on the holidays but there are so many deals. Lol. But long story short, video monitoring with recording features all available from any of my devices. Can’t wait to be able to implement it.

Thanks for your help.

I have gone back and checked all of my connections and tested every screw. We may just have to leave this one as one of those gremlins that we never figure out.

Let’s just hope it doesn’t happen again. I just ordered ten new bits, I hope not to break any of them too soon.

Thanks Allen.

Actually checked that, do not think it was the issue.

Much appreciated

My apologies, I was incorrect. You showed how you extended the power cord and connected the wires.

Sorry for the inconvenience