Lets us know how you make out with the new sensor.
RICH

If you scope then make sure you scope both ends, ie direct at the sensor will let you know so much but if it goes through a BOB then it could well be that that is causing issues.
Hood

I hooked up a C3 board from Aurturo that i had and forgotten about and a opto ,same result ,the first switch checked out fine on the scope  gave a nice 2 to 5 mill sec pulse.
 Just what Mach requires to see the pulse so i guess the board is the next logical step to check ,man what a pain for a few thread's ,i wrote Aurturo to see if he had a suggestion for a board.
 I have a Probotix board on that second port ,i had from another mill project when i went to servo's i do not believe it is buffered and this could be the problem i am facing . I am going to try and read some on that board and see what is up with it.
 

Sorry for the mistake on the buffering it should of said , that the board was not buffered.

Just thought i would update everyone ,i ran the sensor  through my port one BOB with the same result speed sensed but mach still refusing to pick up a thread . Could some one post me a G code for a thread that they created in the wizard and has been successfully run.
 I am still thinking i do not have something set right somewhere and i am over looking it .

It certainly does seem strange that RPM is reading OK and your index etc LEDs are fine.
The threading code I posted the last day I ran but afraid if its wizard code that is tested it will be tomorrow before I can do that as its 11pm here and the workshop is 10 miles away

Hood

Code from the wizard for a 1/4-20 thread. Tested and works.

RICH

Thank's Rich ,i will give it a try and see what i get .

Thank's Hood Rich ,sent one and i will test it and see what we get , just can not figure this out ,i am sure it is a simple thing i am missing somewhere .
 As i have tested two completley different sensors and BOB's with the same result it must be an error on my part or a software issue.

Hi Rich, why the -.3 in the Z start box? i have been using zero there.