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Common Causes

• Actual over-travel condition where X-axis was driven beyond safe travel range due to programming error or incorrect work offset
• X-axis limit switch is misadjusted or mounting bracket shifted causing premature actuation before reaching actual travel end
• Limit switch dog or trip flag bent or loose allowing contact with limit switch during normal axis travel within expected range
• Electrical noise or damaged wiring causing false limit switch signal to IOCON input when X-axis is not at travel extreme
• Failed limit switch with internal short circuit providing constant closed signal regardless of X-axis position

Troubleshooting Steps

1. 1Step 1: Check Diagnostics page to identify which X-axis limit switch is active showing plus or minus limit input status
2. 2Step 2: Attempt to jog X-axis slowly in the opposite direction from the active limit to move away from switch and clear alarm condition
3. 3Step 3: Visually inspect X-axis travel area and verify limit switch dog is properly positioned and not bent into contact with switch body
4. 4Step 4: Manually actuate the X-axis limit switches while observing Diagnostics inputs to confirm both switches function independently and release properly
5. 5Step 5: Check X-axis limit switch wiring for damage or loose connections at both switch terminals and IOCON board input pins
6. 6Step 6: If limit persists with axis clearly not at travel end replace suspect limit switch and verify proper mounting adjustment per machine specifications