Hello,

Mach4 / ESS has been working fine for me, until yesterday. I was running this G-code 15 times, and then suddenly Mach4 starts crashing mid G-code. ESS and Mach remains enabled, but the spindle stops, the motion stops, and I cannot reset nor jog any axes. I can still start and stop the spindle. There is no error displayed in Mach, but looking at the ESS led for E-stop I can see it is lighted up. VFD, Servo drivers, relays, breakers etc. are all fine, no alarms. Only the ESS e-stop led is lighted up. All servo motors are still enabled.

Please find attached G-code, which was working fine for 15 runs today, and one year ago I ran it 50 times without any issues what so ever.

Please also find attached log file from Mach. I've also added a screenshot of a suspicious section of the log file.

Does anyone have any idea what may be causing this? Could my ESS plugin have gone corrupt, and requires a fresh installation? What about the Mach4 profile, could that go corrupt as well causing similar issues? It would be a massive challenge to setup a fresh Mach4 profile...

Thanks for ANY advice!!

Best regards,
Kim

Here is the suspicious part in the log.

Here is my G-code.

And finally here is the log file.

Tried to install latest Mach4 version and ESS v320. Still same issue occurs.

Hi,
I do not think it is the Gcode, you have after all used it a number of times.

Look at the end of the log file. You'll see repeated activations of the ESS Estop signal over only several milliseconds.
Likewise prior to that series of events you have a signal 1186 'FeedHold Not Allowed' there again over several milliseconds.
Both suggest electrical noise.

Do you have physical filtering, ie a RC filter on each input? Do you have any software filtering in the Pins Config page for both inputs?

Craig

Issue found!! Faultry electric motor on my dust collector! It startdd emitting crazy EMI, identified by monitoring ESS diagnostics and turning on/off the dust collector.

Thanks, you we're spot on with your assumption that there were some issues with EMI!