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Question #: 591

Question: THE SWITCHES KEEP TRIPPING! AT TIMES IT IS LITERALLY AS SOON CLICK RESET ON MACH 3 THEY TRIP AGAIN.

Current Solution

http://buildyourcnc.com/PrimeronHomingandLimitSwitches.aspx
There is a pin setting in Mach3 that says how to react to the inputs from the switches. Your setting is probably wrong as the trigger happens immediately.

You may want to think about shielded wire and/or a resistor on each limit switch line. If there are stray wires, connect them to ground. Additionally, the shield from the shielded cable insulation should alse connected to ground at both ends.
Try upping the Debounce interval in Mach3. You have to adjust the debounce interval. You go to config,general config, and it is in the top right corner. I set mine to 100 and it seems to work well.

Additional Information:
how to solution cnc revo 540 limit tripped error?


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Other Possible Solutions to this Question

  • [575] I had limit switches working and on input 2. Now looking at Mach 3 diagnostics, Input 2 is continuously on and triggers limit stop. I removed all input 2 so the machine can run. Rebooted all. Anyway to reset Input on card?
  • [575] I have finally got my limit switches wired and working - thank you. Can they also used as homing switches and if so it it just a question of looping the two inputs on the board i.e. the limit and home terminals IN2 to IN3

    You will want to connect the homing switches (which may also serve as your near limit switches) to different input terminals. It's ok to add more limit switches with the home switches, but each home should be on independent inputs. For example, connect home X and any other limit switch to IN1, connect home Y and any other limit switch to IN2, and so on. This will allow you to properly use the "ref all home" button in Mach3.

    Additional Information:


    Additional Information:
    In the instructions (diagram 1) you show all the home switches connected in parallel? But here you say they need to each have their own inputs. "You will want to connect the homing switches (which may also serve as your near limit switches) to different input terminals." I dont see how the second and third axis can go home if the first axis has already closed the parallel circuit unless they back off a bit until the switch opens up again before the next axis goes to home? My machine has no limit switches so I assume they are home switches.

    Click the link to add information to this solution:
    [575] I have finally got my limit switches wired and working - thank you. Can they also used as homing switches and if so it it just a question of looping the two inputs on the board i.e. the limit and home terminals IN2 to IN3

  • [246] What is the steps per mm on original white ant z screw 314.96 is not right and trying to get it working again

    That z-axis lead screw travels one inch with 5 turns.

    Use the formula:

    steps/inch

    The steps will be the motor natural steps multiplied by the microstepping = (200 x microstepping)

    The number of inches is the travel for one motor revolution = 1/5

    Lets say the microstepping is 1/2, then the steps per revolution is 200 x 2 = 400

    So: 400 / (1/5)" = 400 / .2" = 2000 steps per inch

    The driver will have a dip switch that will show the microstepping setting.

    Click the link to add information to this solution:
    [246] What is the steps per mm on original white ant z screw 314.96 is not right and trying to get it working again

  • Spindle is making a strange sound for a few seconds then shuts off. It is also tripping the breaker on the surge protector. Is this fixable? https://youtu.be/aofbvY3RnIw

    Yeah, that is not right at all. I think you either have an issue with the shaft, or the bearings are bad. Probably the latter. How old is the spindle?

    Additional Information:
    I bought this off craigslist so it is at least 3-4 years old. I've been hearing an odd noise for the last week or two so I'm thinking it was starting to fail.

    Additional Information:
    I would say that it has lived its life. In CNC routers, routers will last far shorter time. Spindles are relatively inexpensive, so I would just replace it.

    Click the link to add information to this solution:
    Spindle is making a strange sound for a few seconds then shuts off. It is also tripping the breaker on the surge protector. Is this fixable? https://youtu.be/aofbvY3RnIw

  • LIMIT SWITCHES FOR AXIS. THE PRINT SHOWS THAT YOU CAN WIRE LIMITS EITHER N.O. OR N.C. SO IF THIS IS CORRECT I WOULD NEED TO TELL BOARD IN SOFTWARE HOW LOOK AT THESE LIMITS, I'M GOING GET AN INPUT LOOSE DEPEND ON IT.

    BYCNC Response:
    This is correct. You will need to use a method appropriate for the software you are using. Also remember that NC switches are typically wired in series, while NO switches are normally wired in parallel.

    User Response:
    I am using the cnc planet software for your USB board. Are the limit configurations in this software?

    BYCNC Response:
    Yes, Planet CNC software is compatible with the use of limit switches. Configuration information will depend on your specific application. You can view Planet CNC's information here: http://www.planet-cnc.com/files/CNCUSBController.pdf

    Click the link to add information to this solution:
    LIMIT SWITCHES FOR AXIS. THE PRINT SHOWS THAT YOU CAN WIRE LIMITS EITHER N.O. OR N.C. SO IF THIS IS CORRECT I WOULD NEED TO TELL BOARD IN SOFTWARE HOW LOOK AT THESE LIMITS, I'M GOING GET AN INPUT LOOSE DEPEND ON IT.

  • Were are the mounting locattions of the 6 Limit switches on the Blackfoot 4.3

    Here are the recommended locations for limit switches for our CNC machine kits.

    The x-axis limit switches should be located on a single gantry. This makes the wiring of the limit switches close in proximity and more manageable.
    https://www.buildyourcnc.com/images/IMG_6367-800.JPG

    The y-axis limit switches should be located at each end of the gantry. This keeps the switches stationary and impose minimal movement of the wire for better wire management.

    One end of he gantry:
    https://www.buildyourcnc.com/images/IMG_6361-800.JPG

    Other end of the gantry:
    https://www.buildyourcnc.com/images/IMG_6360-800.JPG

    Click the link to add information to this solution:
    Were are the mounting locattions of the 6 Limit switches on the Blackfoot 4.3

  • i purchased a breakout board from you guy and the rnr motion control is messing with my license in mach 3 tech support at mach said it is the rnr software i need help to contact them and let them see what they can do to help

    The RNRMotion driver will not conflict with the mach3 license. Make sure you have the RNRmotion driver in the plugins folder and the provided xml in the main mach3 folder. Also, make sure to have the mach3 license file in the mach3 folder. If you still experience problems, please give us a call.

    Click the link to add information to this solution:
    i purchased a breakout board from you guy and the rnr motion control is messing with my license in mach 3 tech support at mach said it is the rnr software i need help to contact them and let them see what they can do to help

  • What power supply do you recommend for the spindle and limit switches if I buy the USB Mach3 breakout board?

    Any of the following power supplies will be fine for powering the Mach3 USB controller:
    https://www.buildyourcnc.com/item/24v

    however, the limit switches do not need high current, so the following power supply is sufficient for the task of connecting limit switches:
    https://www.buildyourcnc.com/item/electronicsAndMotors-power-supply-24v-1a-dc

    Click the link to add information to this solution:
    What power supply do you recommend for the spindle and limit switches if I buy the USB Mach3 breakout board?

  • Will Mach 4 work on the Controller board that is meant to run Mach 3?

    The Mach3 USB board found here: https://buildyourcnc.com/item/electronicsAndMotors-electronic-component-breakout-Mach3-USB-Board

    Is not designed to work under Mach4. The Mach3 USB uses a plug-in in Mach3 to function as an interpreter, sending pulses and signals to electronics from commands sent to the board from Mach3. This plugin would need to be updated to be able to work under Mach4 but the board manufacturer would need to do this update. So far, there is no plug-in that will work for Mach4 and this board.

    Click the link to add information to this solution:
    Will Mach 4 work on the Controller board that is meant to run Mach 3?

  • I HAVE A 2000 WK 11–3 Z LIMIT SWITCHES GOING TO C10R10 BREAKOUT BOARD . CAN ALSO USE THEM AS MY HOME POSITION WELL. NEED THE WIRING CONFIGURATION

    No, you should not have received two parallel breakout boards in your CNC kit. You can return the extra item using standard shipping with COD. Our apologies for the confusion and the inconvenience.

    I will answer the other question as another FAQ. Please check the Customer Service page to see the answer to that question.

    If you have difficulty finding the answer, here is a link:
    https://www.buildyourcnc.com/FAQ/13636

    Click the link to add information to this solution:
    I HAVE A 2000 WK 11–3 Z LIMIT SWITCHES GOING TO C10R10 BREAKOUT BOARD . CAN ALSO USE THEM AS MY HOME POSITION WELL. NEED THE WIRING CONFIGURATION

  • I am looking at your 3 axis CNC machine kit(part #101) on Amazon. Is the interface on this kit USB?

    The electronics combo with the sku of 101 on Amazon.com includes a parallel interface.

    Click the link to add information to this solution:
    I am looking at your 3 axis CNC machine kit(part #101) on Amazon. Is the interface on this kit USB?

  • The purchase of mach 3 software come in a new box (w/ license) or is donwloaded from an internet link?

    Mach3 licenses are sent via email; no physical media are used.

    Click the link to add information to this solution:
    The purchase of mach 3 software come in a new box (w/ license) or is donwloaded from an internet link?

  • MOTOR GOING TWO DIRECTION WHEN JUST PUSH UP. IT WILL GO DOWN AND THEN GOES AGAIN UP WITH THE SAME BUTTON.

    Try slowing your feedrate down and increasing spindle RPMs. End-mills will leave a poor finish if you go too fast. Make sure your cutting depth isn't too much. Maybe the endmill or cutter is blunt? Could it be the feed direction of the cutter? Some materials need to be fed in a certain direction.

    Click the link to add information to this solution:
    MOTOR GOING TWO DIRECTION WHEN JUST PUSH UP. IT WILL GO DOWN AND THEN GOES AGAIN UP WITH THE SAME BUTTON.

  • USING MACH3, MY MACHINE STOPS IN THE MIDDLE OF A PROJECT. HOW CAN IT BE STARTED AGAIN FROM POINT STOPPED?

    Dealing with a mid-stop cut via Mach3, you will have to be careful if it is intentionally or unintentional. If you desire to stop your machine while in the middle of a cut be sure to stop it when the machine is moving in an upward motion on the z-axis and the X/Y-axis are stationary. Then you can choose the point (G-code) where the machine was left off and click on the Run from here button on the Program Run screen (left hand side) right above the Reset button.
    (Make sure spindle/router is running before hand!)

    Now if the machine stops unintentionally, and was moving in either the X/Y-axis, then it will be difficult to run the machine from the original point dealing with the coordinates might have been lost due the the machine continuing motion but via Mach3 the machine has stopped.

    If this occurs to fight this issue before hand, is marking your home with the spindle/router to make a hole were your home is. Although moving it manually back to home the machine can be off by the smallest amount and could cause an inconsistent cut. If accuracy is something that can not be risked, then you can home the machine about a 1/4" or 1/2" down from the original home to start your cut on the same material but loosing that small piece.

    Additional Information:


    Additional Information:
    My typical go to solution is:

    - Note the current g-code line where the machine stopped.
    - If Mach3 errored and you cannot control the machine, Exit Mach3 - you may find that reset, stop does nothing to stop the spindle. When you exit mach3, the spindle will stop automatically.
    - Restart Mach3. The DRO (Digital Readout) should show the correct coordinates where the machine position was before exiting Mach3.
    - Scroll to the g-code line where the machine stopped. You may need to go a few lines prior to make sure you are not skipping any machining operations (which is why it is a good idea to learn the basics of g-code - don't worry, it's easy)
    - Click on the "Run from Here" button.
    - Mach3 will present you with a "Preparation Move" dialog box with the location that it will move to. If the coordinates shows a position that is into the material, make sure to specify a rapid height (clearance height) so the machine will move up first and then move to the location before moving down into the material. If the spindle is automatically controlled by Mach3, make sure to check the turn spindle on checkbox. If not, make sure the router or spindle is on before clicking OK.

    Additional Information:
    My cnc router stops at gcode line 50,000 and cannot finish program. They are about 150k of lines total. I have Mach3 and have bought the additional line capability. Is 50,000 (or around that) the limit? Is Mach 4 hobby license better and in what ways? Thanks! Mike Huber

    Additional Information:
    If you have a license for Mach3, then you should be able to run g-code indefinitely. I think there is something else going on.

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    If you have a license for Mach3, then you should be able to run g-code indefinitely. I think there is something else going on.
    What else could be going on?

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    USING MACH3, MY MACHINE STOPS IN THE MIDDLE OF A PROJECT. HOW CAN IT BE STARTED AGAIN FROM POINT STOPPED?

  • What causes one of my two x-axis motors to stop while the Mach 3 program is still running?

    If one of your stepper motors decides to stop moving and the others are moving during a CNC milling or laser cutting job, then there could be two things that could be causing this.

    - The motor found its limiting torque (usually comes with a not-so-pleasant sound). This is where the control software is trying to move the stepper motor too fast (velocity, or too fast too quickly, acceleration) and the load against the stepper motor (inertia of the machine, or the material against the end mill while milling). Recommended action is to lower the velocity and/or acceleration, and/or lower the feedrate when cutting.

    - There is a wiring issue with the wiring from the driver to the motor. This could be a loose wire, or a chafed wire (or two shorting together). It can also be a loose digital wire from the controller board to the driver. Sometimes wire ties can be the culprit. Recommended action would be to thoroughly inspect the wiring.

    It's probably not the limit switches since that would cause a stop to the entire motion of the cnc router or laser machine.

    Sometimes Mach3 will show a status when something goes wrong, but in cases where the motor is stopping due to its torque limit, then that would not be shown in the status. It's always good to check it anyway.

    Additional Information:
    I need to clarify my situation a little better after going to my shop and trying to run another program on Mach 3. About 15 minutes into the milling process all the motors (2-X axis, Y axis and Z axis)stop but the program continues to run. I stop the program and after a couple of minutes when I try to restart the program all the motors start working again. Then after another 15 minutes or so, all the motors stop again. I checked and rechecked my wiring. This has never happened to me before when running the same programs with the same setups and motor speeds. All of a sudden when I reloaded a program I successfully used before it does this. Do you have any recommendations?

    Additional Information:
    Yeah, it sounds like a more complex issue. Have you tried running in the air without using the spindle. This may be a power related issue.

    Additional Information:
    That's exactly what I did. I ran the program without the router motor on just to see if the motors would get through the whole program but they stopped working after about fifteen minutes and then I was able to start them again after about 3 or 4 minutes. I never had this problem before so you can imagine my frustration especially after ruining a couple of projects on expensive material.

    Additional Information:
    Sure. I can completely understand. Try this: disconnect all but one of the driver from power and digital connection and do the air run. Repeat this for each driver and note your findings. This will rule out the drivers causing a power failure.

    Also, is your stepper motors and drivers on a separate power circuit from the computer?

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    I will try disconnecting each driver and digital connection, which will be a real pain because it will be hard to access.

    All the stepper motors, drivers and computer are plugged into the same power strip.

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    Ok, so there is no power failure going on, but I believe it is necessary to test each stepper motor and driver pair individually. Hopefully that will lead to a conclusion.

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    It will take a little time but I will do it and report back on my findings.

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    Curious, what machine is exhibiting this problem?

    Additional Information:
    I purchased a BYCNC kit back in 2009 with an approximate cutting area of 2' X 4'. I later changed out the Z-Axis Motor and controller for a larger one and have two X-axis motors and controllers. In 2010 I rebuilt the machine out of birch plywood instead of the particle board that the kit supplied. I sent Patrick pictures to him. The machine never gave me a problem till now.

    Additional Information:
    Thanks for the update. This is Patrick by the way. I answer pretty much all of the Customer Service questions. That machine has given quite a good history.

    Additional Information:
    I love the machine and made a number of samples of my work for my e-commerce site, but I can't start selling product until I know this problem is solved because I will not be able to fulfill orders. I finally got all the electronics out of its enclosed protected area near the machine so that I test each controller as you recommended. I hope the problem can be rectified. Will let you know.

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    Thanks.

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    I tested each stepper motor and driver pair individually and they worked so what might be the next step?

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    Did each stepper motor driver pair work for the full +15 minutes?

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    Yes, I had them in operation for over 30 minutes.

    Additional Information:
    Ok, well it’s good that the motors and driver are ok. We are now down to the power supply and the breakout board as possible causes for the stop. I have a feeling it may be the power supply where with all three drivers drawing current and the power supply maybe getting too hot. Is the fan in the power supply working? You can also test to see if there is 36 volts on the power supply voltage output (V+ and V-).

    Regarding the breakout board, if you have an oscilloscope, you can test if the driver pulses are outputting, but I would consider this as a last resort after you determine if there is a problem with the power supply.

    Additional Information:
    I tested the power supply with a voltmeter and each output was registering 39-40 volts. I think the problem may be the g-code. I am using V-Carve pro to do design and output to Mach 3 Mill g-code. When I studied the g-code lines I noticed that further into the program the z-axis g-code stopped zeroing out to move to the next part of the carving. In other words both the x and y keep moving and the z just stopped working because there was g-code missing. I think something is missing when the design was converted to g-code. I noticed that when I ran a simpler project it worked without problems so I need to investigate this further.

    Additional Information:
    New Update, Its not the g-code. I started to run the long program and everything was working fine until about 45 minutes into it, all the motors stopped working (but the program was still running) and there was a high pitched hum. When I put my hands on the motors they were all trying to move but it seemed they were all stalled. I turned the power off, gave it a minute and when I turned it back on I was able to move the motors again. Could this be a power supply problem?

    Additional Information:
    It does sound more and more like a power supply problem. Did you test the power supply after the motors stopped?

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    No, I did not. What should I be looking for.

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    It’s good that you know the voltage during normal operation, so you have a base understood. If the power supply is the problem, the voltage will be reduced or non existent when measured after the problem.

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    Also, check to see if the fan is running on the power supply when the motors stop. That may (not absolutely) be an indication.

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    I'll run another test, check the voltage and fan when the problem occurs and let you know. Thanks for hanging in there with me as we try to resolve the problem.

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    It’s my pleasure. This service is rarely used and is faster then email. Odd nobody uses it. Any recommendations you can give would be great. No problem using this FAQ to pose ideas as this resolution will be cleaned up later.

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    It might be that people do not realize you can communicate through the sight like this because they are so used to e-mail and texting. You may want to explain this feature in the customer service section.

    I ran the program this morning and it did not take long before the motors stopped. While operating the voltages for all three motors was 46 volts, when the motors stalled (and again there was a high pitch hum) the voltage went up to 60 volts and the fan on the power supply was operating.

    Additional Information:
    So, the driver work individually, but not all together. There is a high pitch sound when the motors fail. You have noted 60 volts from the power supply and the supply fan remains on. This is a difficult issue to resolve, but it seems to me that your power supply may be bad. The 60v measurement tells me that the current dropped and ohms law tells us that is current drops, volts will rise if the resistance stays the same.

    Additional Information:
    As one last test I am going to test each driver again and let them go through the entire program because it seems that the failure can occur at the beginning or towards the end of the program. When I originally tested ach driver I let them run for about a half an hour and the program takes over an hour to run completely. I just want to make sure that it is not the drivers. I will report back when I finished but as you noted it may be the power supply but I want to make sure.

    Additional Information:
    That’s a great idea.

    Additional Information:
    I just ran the x-axis through the whole program and there was no problem especially since I have two NEMA 23 motors moving that axis. Before I check the Y and Z could having a NEMA 34 on the Z axis with appropriate controller be a problem. I used the larger motor on the z axis because the router I am using is a large 1 1/2 hp. I've run this program in the past with this set-up and have not had a problem.

    Additional Information:
    Having a, say 3.0 amp driver, driving a stepper motor that typically requires a 6 amp driver would not seem to be an issue since the driver is limiting the current draw, but the driver may not be able to handle larger coil and back EMF with the protection on the 3.0 amp driver. With that said, I don’t believe that is the issue in this case.

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    I don't either because I was able to run this and other complicated programs with this set-up in the past. I will let you know on the y and z axis.

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    Thanks

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    I ran the Y axis and z axis separately through the entire program and there was no stopping or problem. I guess the culprit is the power supply and I'll order a new one and hope that resolves the problem.

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    Yes, that is the most probable cause. Please keep me informed. Thanks!

    Additional Information:
    Received and installed the new power supply. I ran the program with the router on and it worked flawlessly. The program runs for an hour and a half and I did not have a single problem. I guess it was the power supply but I was glad to go through all the diagnostics we discussed before replacing it. I hope this power supply lasts a lot longer than the last one. Thanks much for hanging in there with me and coming up with the solution.

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    It’s my absolute pleasure and I am so happy to hear that the power supply replacement solved the problem.

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    Y axis stop working X & Z work fine Y axis has two motors have check wiring & connections new breakout board still the same port & Pin set OK dont no were to go next David

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    my cnc plasma cutter will run out the program when cutting. what is the cause?

    Additional Information:
    The cnc plasma question shod be a separate question. Can you pise that question by clicking the customer service live menu button at the top? Thanks.

    Click the link to add information to this solution:
    What causes one of my two x-axis motors to stop while the Mach 3 program is still running?

  • Installing THC to my limit ports on the breakout board. Once wired how do I get Mach 3 to reconize the port?

    Getting continuity from the x--/x++ might not mean it is a faulty board, unless they are bridged, so both get a pulse rather than one. But to check if you might have a opposite connection for those input:
    Planet-cnc/file/settings/input/invert inputs/input 1/input 2.

    Additional Information:
    In input port section in config. Scroll down and you will see THC On, Up and Down. Enter your input pin numbers there.

    Click the link to add information to this solution:
    Installing THC to my limit ports on the breakout board. Once wired how do I get Mach 3 to reconize the port?

  • When I start my spindle I get a emergency stop in Mach 3. I have run shielded cable and it is grounded at the VFD it is wired per you site instructions. any idea what to check

    You will definitely want to adjust your debounce setting in mach3 if your emergency or limit switch is engaging.

    Additional Information:
    Did you ever fix this issue? I am having the same problem.

    Additional Information:
    Did you ever fix this issue? I am having the same problem.

    Additional Information:
    Did you ever fix this issue? I am having the same problem.

    Additional Information:
    Did you ever fix this issue? I am having the same problem.

    Additional Information:
    Did you ever fix this issue? I am having the same problem.

    Additional Information:
    Did you ever fix this issue? I am having the same problem.

    Additional Information:
    Did you ever fix this issue? I am having the same problem.

    Additional Information:
    Did you ever fix this issue? I am having the same problem.

    Additional Information:
    Did you try changing the denounce setting?

    Additional Information:
    Meant to say denounce.

    Click the link to add information to this solution:
    When I start my spindle I get a emergency stop in Mach 3. I have run shielded cable and it is grounded at the VFD it is wired per you site instructions. any idea what to check

  • I have a 2000 WK 11–3 Z limit switches going to A c10r10 breakout board . Can I also use them as my home position as well. I need The wiring configuration

    No, you should not have received two parallel breakout boards in your CNC kit. You can return the extra item using standard shipping with COD. Our apologies for the confusion and the inconvenience.

    I will answer the other question as another FAQ. Please check the Customer Service page to see the answer to that question.

    If you have difficulty finding the answer, here is a link:
    https://www.buildyourcnc.com/FAQ/13636

    Click the link to add information to this solution:
    I have a 2000 WK 11–3 Z limit switches going to A c10r10 breakout board . Can I also use them as my home position as well. I need The wiring configuration

  • I can not get my limit switches to work properly on my Mach3 USB controller. I know I have it wired correctly. I can not reset mach3 by either the reset button or the squealy line button below the exap button without unplugging the 24 volt power supply. I have watched the youtube videos at least 20 times and verified and triple verified the wiring. I can send photos to an email address.
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