SX3 External E-Stop error

[metalworkz]

Today while machining an aluminum part from .25" 5052 material and about half way thru the profile passes my SX3 stoped with an External E-Stop error for no apparent reason? I could not clear the alarm and when using the Mach3 controller help to 'Fix' the problem the E-Stop did not work with the active low setting unchecked. I could not find the cause of the error but was able to get the machine working correctly after resetting the Active low for the E-Stop and powering off the SX3 and re-referenceing the machine.
I am wondering if anyone else has experienced a similar problem or if someone might know the cause of this situation? Although I got past the error I would like to find the cause and fix it if possible before I have any more such difficulties. I thought maybe something might of shorted to the E-stop button from behind the Front Display as I have not implemented any of the fixes for the shorting of the display? Thanks for any help or suggestions.
Regards,

[thackman]

I had issues with the front chip shield randomly swinging open and causing E-Stop errors and w/ it catching on the stock. I've since put the mill in a full enclosure and removed the chipguard. With a collet chuck in the spindle most of the endmill was below the guard anyway.

[presslab]

I had problems with noise on my estop circuit, as well as my limit switches. I soldered a 0.1uF capacitor to the back of the break out board across the estop connector leads and that fixed it. With the limit switches I used the holes where the unpopulated connectors went.

[Chrisjh]

I had a similar problem last week. Turned out to be a pin inside the plastic housing on the cable between the spindle control board and the spindle driver board had pushed out . The pin happened to be the E stop signal line.

These pins are very tiny with a "fish hook" style barb. In my case the barb was OK but the barb had neatly cut a groove in the plastic housing allowing it to push out when I engaged the cable connector to the mating receptacle on one of the boards. Took me 2 days of cursing and swearing before I found it.

In my opinion, these computer style connectors are not robust enough for this application. I have had trouble in the past with this exact same problem on a different cable on another SX3 machine. That one was the cable between the LCD Board and the Spindle Control board.

Watch out for this probem when inserting cables onto the various boards. I now have learned to carefully inspect each cable following every insertion.

Regards

Chrisjh