I have an idea I will check tonight. I have the "Charge pump runs in EStop" unchecked in the ESS settings. Maybe my BoB could be holding the limit switch circuit hostage until it sees the ESS provide the charge pump signal?
This is from my BoB manual.
"Charge pump circuit and enable signals
When there is no E-stop condition and the Mach3 software based control is running
properly, Mach3 outputs a steady pulse stream to the IO6 breakout board. The IO6
receives this pulse stream and sends an enable signal to every axis mod jack
connector, on mod jack pin #4. It also enables all outputs of the IO6. If this pulse
stream is interrupted, the IO6 will correspondingly disable all outputs from the IO6.
This safety circuit prevents spurious outputs from the PC from producing unexpected
results.
The charge pump circuit energizes a relay that provides a pair of bare relay contacts,
and +5V & +24V enable signal for system integrators to use to implement other safety
measures. We also provide direct access to the charge pump signal. This phoenix
terminal is located on the Auxiliary Terminal Block. (See Figure 2)"
My E-stop and limit switches will kill the drives and stuff regardless of the ESS condition, so I am going to try turning this option on in the ESS so that it keeps the charge pump alive to see what happens.
I may need to rethink how I have my limit switches and E-stop wired with Mach4. Not sure yet. What I have now is very effective for safety though. The limit switches basically produce an E-Stop condition since they are in series with it.