Ok, reply from CS-Labs, my comments quoted in the reply start with >>>....
Dear Dave,
>>> As you can see, the system started up normal, then had a software limit switch activated - this was caused buy this line of code - G28 G91 Z0.
Soft limit limits are set out and passed to CSMIO/IP-A by Mach3.
If Soft Limit was set correctly the obviously Mach3 made a mistake during Soft limit calculations or during passing to the controller.
>>> Then once i reset Mach it followed with an ePid fault on this line I think - G0 X109.987 Y168.641 or this one - G43 Z25. H2 which followed.
The e-PID mens too high difference between currently set by Mach3 trajectory and currently set axis position read out from encoders.
The fault may be caused by Mach3 and servo drives as well.
- E-PID caused by Mach3.
The fault is mostly caused when Mach3 makes a mistake during calculations and it wants to perform very fast uncontrolled axes move.
A corrupted XML file is usually responsible for that. The e-PID fault may be also caused by incorrectly written VB macros.
e-PID caused by servo drives.
That's nothing else but max. following position error exceeding of one of axes.
In this case you should verify your PID loop settings (tuning).
I would only like to add that for a milling machines we always use 03.043.022 Mach3 version as it's the most reliable in our opinion.
Version higher than 03.043.045 of Mach3 can sometimes cause problems with synchronization of internal coordinates so it's easier to get the e-PID fault.
Now, in my mind this looks like an internal Mach/CSMIO thing because in theory you should NEVER be able to exceed or trip a soft-limit - thats the WHOLE reason they exist, to control the boundaries of motion right?
So, somehow, my code for home is trying to send Mach Z axis beyond Mach Z++ soft-limit home setting - this is clearly wrong no?
Any thoughts?
So, it seems i need to downgrade further, anyone have a link for V022 please?