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General Mach Discussion / EStop Request when nothing is moving

« on: December 12, 2012, 05:52:13 PM »

I am having a problem where the "estop was requested" thing shows up somewhere between 3-9 minutes of Mach3 being active.  If I have mach3 active, but have NOT MOVED OR TOUCHED anything on the machine, somewhere between 3-9 minutes, the RESET switch starts flashing.  The only way to deactivate it is to close the mach3 program and start all over.  If I am cutting an item, within 3-9 minutes it stops mid cut and says estop was requested.  To reset I have to close mach3 and reopen the program. 

The machine is a Probotix V90, and has run flawlessly for six months.  All wires are shielded, sturdy switches used for limits, requiring 1-1/2 lb of force to activate.  Have tried debounce with no difference.  Had it always set on 0 before, without issue.  Can NOT set estop to ACTIVE LOW, as some people do, because RESET will just flash all the time, no matter what.  I've left ACTIVE LOW off for the past six months and system worked without issue. 

When estop is activated for unknown reason, the diagnostic screen shows the estop with a red "LED", but no other lites are lit on the diagnostic screen.

Gecko G540
Windows XP (CNC dedicated PC)
4 GB Ram
Dual Core 3GHz Processor
All Wiring is Shielded
APC 1500VA Power Back-Up