Hi again.

I wired the switches and e stop did the setup as cropwell said. All fine until I power up the steppers, and then I get noise problems again, limit switches triggered, external estop requested message which sometime does not reset.
I disconnected the vfd and still no good.

As adviced by Clive S, I did more research on this topic, and ironically, that raised more questions.
1. is it a bad grounding practice to pigtail for example the stepper shieldings, and then run a ground wire to the mains earth, or should I run a separate ground wire from each shield to the earth. Does it make a difference?
2. as the spindle is set on conductive material, it.s ground wire becomes the framework.s ground as well, and running another ground for the frame will only create a ground loop. is that correct?
3. does the fact that having all components in one enclosure, raise this kind of problems, even if all wiring and grounding is done correct? should I have 3 separate ones, pc, stepper control, and vfd?
4. all wires run in the cable drag chain, meaning I have low and high voltage right next to each other. so from all I found online, the easiest way in my opinion is to add a relay next to the breakout board, and have the limit switch wires at 12 or 24 v. or should i physically separate them a couple inches apart, or improvise a separate carrier for the low voltage wires?
5. for estops and limits, I have an "hardware" and a "software" estop, one to a contactor, one to mach3, is it useful or necessary to approach the limit switches in a mechanical way? (like some relay which kills the power to the driver, or source)
6. in the vfd manual it says that you should not use a contactor as a switch for the vfd. So i use a cam switch to turn it on, but wired after the contactor, so hitting the "hardware" estop, will kill power to everything, turning just in this cases the contactor into a switch. The I reset the cam switch to zero, power up the contactor again, and turn on and off the vfd from this cam switch. Is there any problem in this wiring method?
7. except the vfd main, where else should ferrite accessories be used? sources mains, between sourced and drivers, breakout board 5v wires.
8. does the breakout board, being close to the drivers and/or vfd, can cause noise issues?


I.m considering taking all the electronics apart and start from scratch, a better cleaner design, easier to troubleshoot, and would appreciate very much an advice on how you would do it. Assuming you have in front of you all the parts involved, how would you design it, in order to never, or at least most of the time, not encounter this kind of problems.