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Fault output relay 17 has continuity between COM and NC terminal with no power applied to MPU11 and GPIO4D boards. My GPIO4D board is labeled different than what your 2010-08-17 install manual shows. My E-stop circuit works fine between Mach 3 and GPIO4D board, output 1 engages and disengages as described. Relay 17 as etched on my GPIO4D is NC-NO-COM. Is this a problem? With my relay wired as per manual, I have continuity between NO and COM terminals. The E-Stop circuit operation does not affect relay 17 outputs. Any answers? Thank you, Metalstech . MPU11, 9/25/09 101509 0082. GPIO4D, 7/16/09 version 0003. Mach3 version 3.043.022 Ajax Plugin version 1.16 Copley Junus drives.

Metalstech wrote:Fault output relay 17 has continuity between COM and NC terminal with no power applied to MPU11 and GPIO4D boards.

That sounds like expected behavior for a normally closed circuit.

Metalstech wrote:The E-Stop circuit operation does not affect relay 17 outputs.

Do you mean a software estop in Mach is not affecting relay 17? or your physical estop switch is not affecting relay 17?

I do not believe the physical estop should affect relay 17. From what I recall that relay only tripped when I would hit reset from inside Mach.

Output 1 only should trip on a PLC event like loss of communication with the MPU11.

I had what sounded like similar problems upon first reading your post. In my case it was ultimately resolved with the inclusion of a Mach Brain in a later plugin release. A brain needed to operate "Fault Out" Output 1 which was not occurring before with Mach when wired according to the instructions. http://www.ajaxcnc.com/ajaxbb/viewtopic ... +out#p1827