Brett,
Well, all the things we discussed have failed to improve the situation. I thought that changing the settings for step and dir pins in the config menu had fixed the problems, but alas it did not.
I replaced the limit switches with brand new honeywell microswitches. They have a distinct make and break that are at different points. The originals had a single make/break location. I thought that maybe some bounce in the switch was causing the problem.
After hooking up the new switches, and turning the machine on, everything worked. It homed just fine TWICE! in a row. I thought OK now I've got it licked. Dry ran some code. Tried to home it. It froze up on the Y switch without backing off. The screen did not show any error, but the diagnostics screen showed the limit was tripped/home switch was tripped. So I put it in overide backed off and tried agiain. Still didn't work.
So I turned off the X++ and Y++ limits. Still didn't work. Then I turned off both X-- and Y--. Tried to home it again. It went right through the home switch without stopping.
There is some flat out flaky behavior here that can't all be my hardware. I've tried new switches, double checked the sheild grounding, played with settings till I'm blue in the face. When I first start the machine, it will work. Then it just gets plain weird. Sometimes it will do like it should and the Z will home, then the Y, then the X. Sometimes the Z will home, then the X and Y will both take off at the same time until one of them hits a home switch and then everything stops no error, nothing. If I hit Estop then hit it again it will give an error and say limit switch triggered. Sometimes all three will take off at once. Sometimes the Z and the Y take off at the same time.
I also found that once I triggered the digital outputs for flood and mist, the only thing that would shut them off is to reboot.
soft limits do not work
I'm out of ideas.
Monty