Please don't assume you are conversing with an idiot. 20 years ago, I was automating machines from the 1800s, converting all of the hand driven levers to hydraulic actuators with limit switches and hand-off-auto stations. I even set up hopper feeders etc... The next job I had at a torch tip factory, included building machines that didn't exist until our engineering team built them. I put in more time than anyone into those projects. Point is, I have been doing automation and troubleshooting of the like since the mid 90s. I think I can keep track of some limit switches for three axis as well as the estop. What you are saying is condescending. If you want to see what kind of work I do now, look here:
www.volitionamps.com , if I can wire those up, I think you would agree that the wiring we are talking about seems simple by comparison.
I can't count the number of Bridgport mills or Cincinnati lathes that I have installed servos and scales on. I cannot tell you how many Idecs or Slc50s I implemented in years gone by.
I can and do multi-task regularly. I am not just changing stuff at random. I read some of the similar problems and attempt some changes. If I see no change, or nothing in the right direction, I roll them back. I can keep track.
You may not be able to help, but there is no need to assume that just because you don't understand my issue, I am doing heretical things in a haphazard way. My troubleshooting methods are quite refined.
I do admit that this is new to me and others have more experience. That experience can help detect what might be faulty or just mis-configured.
All of this to say, rest assured that my limit switches and estop are connected and functioning properly as far as mechanicaly and electricaly. The interface between Mach3 and the G540 are what I suspect to be bad or mis-configured.
Also, there is a difference between being rather good at something while implementing a new method of arrival and being a total hack. I am the former, not the latter.
I have checked everything you are imply that I should disconnect and recheck. I do this as I go as a general practice. Maybe we could skip ahead to find the real problem.
Shall I post pictures?
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