6040Z controller

[Doddy]

Having set the programme and machine up so the limit home and soft home all worked I fitted a noise filter as per instructions both having been supplied by a forum member, now the limit and Home switches do not work, it had gone into e stop mode
I have gone through the line and port settings and all is correct, however if I set the XYZ limits to active low the machine does not go into e stop but the limit switches do not work, in diagnostics the limit led do not light up, if I uncheck the active lows the programme is in e stop but the diagnostic shows the led as lit, but they do not go out when the limit switch is activated, I have checked the wiring circuit of the limit switches they are all correct, I have checked the wiring to the Bob from the switches all correct, I removed the filter and replaced the original XYZ leads and went through everything it is exactly the same,
On manual jog if I manually activate a limit switch it goes into e stop, so that must prove the switch circuit
Has to be something simple, I know it is difficult without being on the actual machine, but can anyone throw any light onto this please
Regards Richard

Okay, Richard, there's a lot of information missing for people outside of our conversation here, and in particular what a "filter board" is in this context. Let me fill in the blanks that people will otherwise ask, and perhaps ask a few questions myself...

Having set the programme and machine up so the limit home and soft home all worked I fitted a noise filter as per instructions both having been supplied by a forum member

"Having wired the machine with independent X,Y,Z limit switches, each axis wired with two switches in series in a Normally-Closed mode, onto a modified BoB (shown in images on page 1 of this thread), there were problems experienced with noise on any/each axis limit switches that generated spurious limit triggers with Mach3. We did try to address the noise issue by increasing the 'Debounce' value in the Mach3 configuration settings, however, whilst increasing 'Debounce' did reduce the occurrences of spurious limit trips, they were still evident.

Some kindly soul suggested that, in reviewing the board layout, the BoB simply presents the limit-switch input straight to the parallel port interface with nothing but a pull-up resistor (and privately, possibly a filter capacitor). This means that any electrical noise picked up by the wiring in the machine is presented directly to the parallel port input into the computer, and could be a mechanism for noise susceptibility.

To try to counter this, it was suggested to introduce a commercially-available opto-isolator board, in this case a 4-channel device. In reviewing the schematic for the opto-isolator board, noting the positive-side switching, a wiring scheme was introduced (and modifications made to the board) to support 24V switched limit switch inputs to attempt to improve noise immunity, thus:



and provision of cable assemblies, thus:



and finally with a special-to-type cable assy to connect the opto-isolator board directly onto the board, previously modified with pin headers to access the X/Y/Z limit switches...

now the limit and Home switches do not work, it had gone into e stop mode

I have no e stop fitted yet, should I connect the e stop connection to the 24 common so it looks as if one is fitted

It’s a plan, or set it active high/low in Mach3. ESTOP is normally N/C so wiring 24V to the ESTOP filter board input would work

I have gone through the line and port settings and all is correct, however if I set the XYZ limits to active low the machine does not go into e stop but the limit switches do not work, in diagnostics the limit led do not light up, if I uncheck the active lows the programme is in e stop but the diagnostic shows the led as lit, but they do not go out when the limit switch is activated

At this point, I explained that Mach3 is not an area that I've comfortable advising upon simply because I've not used for several years. Forum members may be able to help.

However, Richard, I did ask for screen shots of the Mach3 Ports&Pins Input configuration settings that covers the axis limit/home switch settings. I believe people will require that to help further.

I have checked the wiring circuit of the limit switches they are all correct, I have checked the wiring to the Bob from the switches all correct, I removed the filter and replaced the original XYZ leads and went through everything it is exactly the same,

Okay, a new request - can you provide a good photo of the wiring loom added into the BoB

On manual jog if I manually activate a limit switch it goes into e stop, so that must prove the switch circuit

Now, I need to ask you to be precise here. Mach3 will enter a fault mode, and identify the cause of this (E-Stop, Limit Switch, etc), that you have to then clear. You say "e stop" - is that true?, that Mach3 scrolls a message that E-Stop is pressed?, or does it identify that the Limit Switch is triggered?, this is quite important to understand clearly.

Has to be something simple, I know it is difficult without being on the actual machine, but can anyone throw any light onto this please
Regards Richard

Very difficult without being on the machine. I keep looking at the map and we're still 150 miles apart. However a 6 hour trip is starting to sound more and more attractive, if it wasn't for this damned Covid crap.

I'm concerned now with the wording of your message that the E-Stop is triggered when a limit switch is activated, because that behaviour as described is unexpected - yes Mach3 should enter it's fault mode identifying the Limit Switch is triggered. This bit, for me is critical to understand better, and part of the reason above I've asked separately for an image of the wiring of the opto-isolator board to the BoB (I want to see the wiring connection onto the BoB - for the 3-way limit switch, the 2-way scavenged 5V supply and the 1-pin E-Stop input). Back into email, I will be asking you to measure signals on pins on the BoB.

But, in asking for help from the forum a context is required which I hope I've half completed - but would be assisted particularly with the image of Mach3's input port configuration page.

BTW, if I come across as being a pedantic sod - I am - as part of my career I've had incredibly highly trained people try to explain technical problems to me - the English language is a poor medium for diagnosis, inevitably when you look under the hood you find that there's critical information missing or misunderstood which only a Mk1 Eyeball will pick up. If I continue to ask questions it's to try to understand more clearly (and at a distance) the problem. And if you don't answer the questions I'll keep asking them (at least until one of us gets bored).

There's also this bit from our email conversation...

The situation is this, everything was set up to work on home switches and limit switches, nothing was altered and the filter fitted and double checked it is connected as it should be. On the diagnostic screen the led lights operate when triggered and show the three different axis. So the filter board must be working as far as signals go.

which appears at odds with the description above. I need to probe you further on this, and the current behaviour of the machine.