[dude_chevy]

The machine can be running just fine, then all of a sudden it throws a limit switch error. None of the axis are no where near a over travel switch. I tried running the machine and watching the diagnostics screen. Watching the over travel lights to see which axis was giving me the error. 2 times it gave the error while I was watching. None of the limit switches lite up. I did notice while it was running the output #1 light kept blinking. Is that normal, or could that be what is causing the problem?

MACH3
G0704 using stock screws.
KL-6050 stepper motor drivers
C-10 parrallel break out board
KL 600-48 48VDC/12.5A Switching CNC Power Supply
nema 23 570 oz (KL23H2100-50-8B)
Micro limit switches (Micro Limit switch | Automation Technology Inc)

Thanks,
David Branch

[rcazwillis]

Is it happening when you are cutting? Is vibration causing one of your switches to bounce or falsely trigger for a moment? I would use process of elimination to identify where the issue is occurring. Disabling one switch at a time until you identify which one is giving the error. Then work through that switch circuit until you find the problem. Could be wiring or the switch.

[dude_chevy]

Thanks for answering my question. I had just thought about unhooking different switches, until I figured out which switch is giving the error message.

It is happening when I am running a program to test, prove it out. the spindle is not even running and no part in the machine.

I am using limit switches that cost about $4 each. I have had this error happen off and on alot, it has just started happening alot. What kind of limit switches do you use?

Also I am using "bell wire" to run my switches. It's a a red and white wire, 18 or 20 gauge. It's a pretty stiff wire, one soild wire, not a bunch of small wire wrapped. I am not an electrician, is there a better wire I should use for that?

[hoss2006]

you should use stranded wire not solid, you probably have a break in one of the wires that is making intermittent contact.
Hoss

[dude_chevy]

I figured out that it was the Z switch and wire system. Replaced the wire with a stranded wire, and used a new switch. It was orginally hoked to port 12. Got the same error after replacing switch and wires. When I unhook the wires from the board the error goes away.So I tried it with port 10 then 11, and get the same thing. Guess my C-10 breakout board is bad. This will be the 2nd one I have had to replace. Are these bad board since htey are so cheap? Is there another brand, or model that is better quality?

David