I really like the Xbox controller and the Xbox plugin.  The configurability is awesome.  I can set all the functions I normally use when setting the machine, or touching off to a part. 

However, I have seen one bug that causes a problem.  Even with the triggers set as a safety sometimes the machine takes Z all the way down until it hits something when I shut down the software, and I even saw it do it when I hit the programmed E-stop button once too.  Is there a fix or a work around to prevent this? 

I actually like the functionality of the Xbox 360 better than my MPG pendant except for this issue.

Its on a Windows 7 Pro 64 bit machine using an Ethernet Smoothstepper if that makes any difference. 

This is happening when you jog? If so it is a bug with how Mach 3 works with external motion controllers. If you are using 'shift jog' and let off the Shift key first the plug-in is never notified that jogging has stopped. If the Xbox controller plug-in is mimicking the keyboard strokes then it likely has the same problem.

This is not happening when I am jogging.  It is happening as described.  

I am aware of the shift jog bug. 

All you say is "Even with the triggers set as a safety sometimes the machine takes Z all the way down until it hits something when I shut down the software, and I even saw it do it when I hit the programmed E-stop button once too.  Is there a fix or a work around to prevent this?", the question is when does this happen? When the machine is sitting idle, when you are running a program etc.? I know some folks had had problems with the Xbox controllers as the joysticks are analog and can creep when just sitting still. Maybe that is what you are seeing?

Never mind I just re-read what I quoted

When you shut down Mach 3 it moves the Z axis?

Yep, but not always. 

That is very odd, the Xbox plug-in has to be sending jog commands as the ESS won't create them on its own. Does the Z axis DRO change when this happens? The ESS counts the pulses it puts out and the DROs in Mach3 get updated based on actual pulses put out. If the DROs change then the ESS is being commanded to move, if the DROs don't change then it might be electrical noise being interpreted as step signals which is doubtful as it is always going down.

do you have a macro pump or Brains running that have anything to do with homing?

I thought it was odd too.  Only thing running are the stock brains.  I found mechanically e-stopping the machine before shutting down seemed to stop it from occurring.  A mechanical e-stop cuts the inputs ad outputs on the BOB.  Its probably good practice anyway. 

Generally an E-Stop should remove power from things that move. So an E-Stop/Safety relay/contactor that cuts the mains to the drive power supply and spindle (etc.) is a good idea. On my small controllers the current involved is low enough that an EStop switch can be used directly but on the Bridgeport I'm working on a safety relay was added to let the 24V EStop chain control the main contactor.

You say your EStop cut the outputs of the BOB? You have a relay in each I/O line? Or, your just cutting the power to the BOB I/O?

Well, I had relays and contactors that were also cut, but there seemed to be some flutter in one of the relays causing a spindle problem on that machine so they are temporarily bypassed.  The BOB is a smart BOB that turns off all outputs when its e-stopped.  If things really go sideways I can always kill the master power.  Gotta love a big blade disconnect for that. 

It doesn't address the problem though, and mechanically estopping the BOB does seem to prevent the problem.  You can lecture me on that tangent some other time.  LOL. 

If you remove the Xbox 360 plug-in does it still do the same thing?