I just got my zenbot 4848 up and running good.   Shaun (zenbot creator) installed my limit switches and sent my xml  lcustom  config file he wrote for my machine  he used a db9 cable for the connector between the switches and g540 controller.  When I start up mach3 I ref all home
it zeros out and everthing was great until I installed a longer db9 cable between the switches and g540.The cnc now goes to all three homes zero out but the x,y,z zero lights stay green.  I switched back to the shorter db9 cable but still have the same problem.I uninstalled reinstalled mach replaced the xml config file but nothing has fixed the bug.  In the diganotics screen port 1 light 5 led stays green.  If I disconnect the db9 cable the cnc works fine jogs around and zeros anywhere I tell it to just no limits.See attachements below for screen shots.  Everything is new cables, switches, g540 and cnc.(  Summing up  When I received my cnc Thursday everything worked and homed.  10ft db9 switch cable was too short replaced with new  25' db9 now port 1 light 5 stays on.  Switched back to orginal 10 ' db9 same problem  Start mach3 ref all home machine moves to zero  with x,y,z lights red untill they home  turn green stay green jog machine away from home but cant zero any new position.  Disconnect db9 everything works fine zero's anywhere I put it.

Can you attach your xml and I will check the config.
Hood

Here's the file Thanks for responding also have a youtube video that will be up in about 2 hours after it processes

Heres the youtube video
http://www.youtube.com/watch?v=yNFee2Q7pZI

Ok go to ports and pins, Inputs and disable the A Axis home switch and see if that helps you.
Hood

That worked you are the man!!!  The port 1 light 5 is still illuminated but it homes, soft limits work and the DRO's zero anywhere I tell it.  One more question my kernal speed is set to 60khz thats how its tuned to the motors when I set it to 25khz per mach3 tips it tells me motors need to be retuned.  Should I just leave it set to 60khz?

Your motor tuning requires just over 9KHz so there is no need for such a high kernel and likely you would be better off at 25KHz.
The A axis however has 900 for Velocity which would mean you would require a kernel of 41KHz, that however is only if it was a separate axis, it is not in your case as it is slaved to X. So set the A back to 200 for Velocity and set your kernel to 25KHz then restart Mach and you should be fine.
Dont worry about what the port pins on the diagnostics page show.
Hood

Hood !

I'm not worrying, but I am a bit curious about what the fifth LED is indicating by maintaining a lit state.  

I've not done any in-depth search to relearn what the diagnostics page tells me in it's entirety, so, if you happen to know off-hand......

By the way, just wanted to mention how your CNC system on that huge green giant you restored has me waiting for your next image or video of almost every time you hit the start button or work around.  O

I dont think anyone has really worked out what the heck these LEDs actually signify, you think you have it worked out then the next computer seems to disprove your theory
I never pay attention to them, similar is the Abnormal Condition button/warning, I think its a real PITA and often makes people think there is something wrong.

Hood