This is still causing a lot of problems, ordered another gecko. Same thing happens, its very strange, just throws an e-stop up after a few seconds. Will only reset upon shorting the e-stop. So I ordered another gecko, same thing, changed all the 4 motors, reloaded mach3, chnaged computer, bought another brand new (different make) 48v, 7amp power supply, charge pump on/off, bought in a large 6800uf capacitor for the power supply, built a whole fresh control box, same problem. It did strangely work for 5 minutes with a 24v power supply.

Any ideas, the only thing I can think is its the gecko G540? tearing my hair out here!

Are you wiring as per the G540 docs?
Hood

Also can you attach your xml as you never did the last time I requested it, could be a simple config issue.
Hood

I'm having the same kind of imaginary e-stop problem.
I think I may have figured out the cause.
Whenever I turn on the shop vacuum to collect some wood chips the imaginary e-stop occurs.
I experimented by powering the shop vacuum else ware and the problem is less prevalent.
However is something big, like the air compressor, kicks in there we go again.

I am running the shop computer and CNC electronics off of a single 15A circuit and the router off of a separate 20A circuit.
The 15A circuit also powers the other shop outlets.
Someday I will have dedicated circuit.

Until then, I'm thinking a small UPS for the CNC electronics.
dougie329, could this be the cause of your issue?
Do you think the UPS solution will work for either of us?

A UPS probably will not help. A line filter will. And moving the PC and the motor power supply to different power circuits can have a positive effect.

Random 'spookie' issues in general can be caused by voltages that are hovering near the ON/Off TTL threshhold. Make sure you do not have a newer 3.3V parallel port driving a 5V BOB.

Assuming all of that is OK, add pull-up or pull-down resistors the the pins that are causing trouble. i.e. hold then up or down away from the threshold.

Practical example: Say your E-stop line goes HIGH to activate E-Stop. Put a 10K resistor between that pin and ground. This will hold the signal OFF and keep it from wandering all over the place from induced voltage. When your E_stop goes HIGH, it will have no trouble driving thru the 10K resistor to pull the pin HIGH. Still, check it to be sure.

Conversely, if your E-stop goes LOW, then put the same resistor frm the pin to 5V to hold the pin HIGH until the E-stop signal pulls it down. Some BOBs have these pull-up/pull-down resistors built in. If your BOB has these, make sure that they are set to pull in the right direction as described above.

if you have Use WatchDogs ticked on general config un tick it if it still happens it could be your computer i have the same problem  i un ticked it it stopped happening my computer just runs it it only happens sometimes