Quote Originally Posted by cpf View Post
I am starting to think that maybe there is a dodgey connection some where as i am unsure as to why this is happening. We have had the pendant apart to check everything is in tact in there and all is fine.
Thank you for your advice!
This won't be a dodgy connection or bad wire issue. It will 99.99% be a parameter change in the pendant or G-code.
Lose wires can't change the size of a part or make it move any further than it's been told to move and still have the part come out the correct shape (assuming the part is correct just larger.?)

To be honest It's typical of the kind of issues these DSP style pendants can suffer from and often they just blow their minds (parameters) and never run again. In this case, it's better to just rip them out and install PC based motion controller.
Often the machine runs better and the PC control software gives far more control and better operator experience.



If you can post the G-code file I will take a look for you and check the code. Just Zip it up and post the file.