I double checked the sensor flag installation.
It is a drive fault.
Appears that the sensor is not reaching the flag
No movement of the Rack
Verified proper air pressure at the regulator, verified airflow at the exit end of the regulator.
No air pressure indicated on the Aux box digital pressure display.
No movement of the rack
More information: There is no air coming out of the dump valve (I removed the output airline) when the Aux box is powered on or off.
Ok, two issues here, letâs take them one by one.
If your machine is moving past the sensor flag on X thereâs a reason for it:
When you manually drive over that sensor does it trigger? You can tell by looking at the amber light on the sensor itself, and the âXYZAâ light on the CNC screen if that is not happening you need to address that. It looks like the flag might be improperly mounted.
No air pressure in the box:
Did you use our new E stop we provided, and did you connect it properly between the aux box and the EX control? If you didnât do that your aux box will be stuck in an E stop state and will not fill with air.
Sensor flag: The sensor is not making to the sensor flag as it travels in the positive X. My bad on the picture description, X is moving positive to the left in the picture (taken from the rear or the gantry).
Ops, the new E stop controller was sitting there right in front of my face. I remember reading about that in the directions. My apologies!!
If it canât make it there is it hitting the end of travel? That would cause a drive fault. If thatâs the case the flag is in the wrong spot.
If itâs not hitting the physical end of travel there must be something obstructing it. If thatâs the case power off the motors and slowly push the machine by hand to see if you can figure out where it is.
The flag is located exactly where the instructions indicate.
The Xâaxis is stopping at the rubber bumper.
I reviewed the assembly instructions for the extended gantry, and they do not show a shim plate on the right side (as you face the gantry). I performed my servo upgrade when the kits were first released, and I remember needing to add a shim â which is why the photo shows two plates. The issue is that the âshimâ I improvised at the time wasnât actually functioning as a shim (I might have thought it to strengthen the stop), since the rubber bumper remained in its original position. It was never a problem because, with the extended gantry, the axis never traveled far enough to reach the stop.
Proposed solution: Install a shim between the gantry extrusion and the rubberâbumper mounting plate.
The shim goes on the side of the machine where your tool height setter is. Itâs meant to make sure the machine can fully reach over it, which in your case is probably a non issue because you have the extended gantry:
To expand on what I am asking here:
When you drive towards X+ does that sensor ever trigger? If not, you need to resolve that.
If the sensor never triggers on the flag and easy way to adjust it is this:
Drive the machine as close as you can get to the bumper. Move the sensor flag as far as you can to the outside of the machine, then move it back until that sensor JUST lights up. Lock it down and try again.
With the bummer removed the sensor triggers after another 1/8" of movement.
The instructions call for â0â between the riser plate and the flag, which is where the flag sensor is positioned.
âDrive the machine as close as you can get to the bumper. Move the sensor flag as far as you can to the outside of the machine, then move it back until that sensor JUST lights up. Lock it down and try again.â
The flag canât be moved far enough to the right to trigger the sensor, it stops at the attachment plate.
Picture below: The X axis + t is moved against the bumper, and the flag cannot be moved any closer to sensor. What am I missing?
Are there different length bumpers?
I am not sure whatâs going on here, but I have a guess:
Your extended gantry isnât mounted correctly. If true this may have never been noticed because up until now you would only have needed that X+ limit sensor if you ran the machine too far, which the software limits prevent you from doing (unless something had really gone wrong)..That is unless you had previously (and successfully) used the âtravel limit setterâ utility.
Can you confirm that distance is correct?
Also in this image can you confirm that your machine is parked RIGHT up against that rubber bumper? If itâs not, youâll need to remove your travel limits (or make them larger) so that you CAN move the machine up against the rubber bumper
I got up this morning thinking the same thing.
Measured:
Left 149.6
Right 150.5
Can you show me a picture of the machine parked at X+ all the way up to the bumper, and show me the relationship of the flag to the sensor.
Give me a picture so I can see everything in one shot⌠the bumper plate, bumper, sensor flag and sensor.
I think there are two things potentially going on here:
That gap might be too big and potentially causing the sensor not to trigger, and are you POSITIVE this dimension is correct:
At this point Iâd just pull off the rubber bumper so you can get the sensor to trigger so you can move onâŚ
Thereâs still something about this build thatâs off in some way and I canât figure it outâŚ
ok, talked it over with some folks here and there are some things you can do to fix this forever:
-Leave the bumper off. That black bumper you have itâs one that we provide (at least nobody could identify it) the ones we send are different, so that might be the root cause there. Youâve got servos that will stop at soon as they hit that end plate so removing that bumper is a perfectly fine solution.
-You can flip the rear stabilizer bar over:
This rear bar is not symmetrical, so if you flip it over it will leave the top channel on the gantry clear so you can put that sensor flag wherever you want.
It it were me Iâd just do option 1. Youâve probably already done it anyway 
FYI: The length of the X axis bumper in question is the same as the length of the bumper on the Y axis which is indeed a different shape.