Hi,

I am suffering from an emergency being triggered in Mach3 for no apperent reason. The error is quite rare some sessions its not there other sessions its happens 10 - 20 times The error obviously stops the machine dead. I can reset and continue normal movements. Sometimes the machine will error and stop when using manual rapid travel to reposition the cutter. I have a latched relay on the Emergency/Limits circuit, if there is a true emergency then I need to push a button to re-latch that relay before being able to reset in Mach3. When this (fake) error is shown in Mach3 the emergency relay is not de-latched. I first thought is was the limit relays bouncing from cutter vibration and becuase it was a very short time period for the error the relay did not have time to de-latch but Mach3 caught it. I ruled this out becuase I shorted the emergency cicuit and it still occurs. Today the emergency was being triggered a lot, this followed me making a change in Fusion360 when post processing, I used smoothing which from what I can tell dramatically reduces G-Code line count by replacing point to point movements with fewer radius movements. The smoothed G-Code wont run but the normal will. The smoothed G-Code is around 9k lines the normal is 32k.
Can anyone suggest a reason or how and where to look first. Its running kit from CNC4YOU, HG08, CW-5045, SwitchMode PSU, WinXP 2.4MhZ
Regards
Simon