Homemade CNC Plasma - hypertherm, Mesa, gear drives, nema 34.

Does sound like an EMI issue.

Have you tried debouncing the limit switch signals?
 ( This can be done with the hal debounce component or with some
hardware, a hal parameter )

RNJFAB wrote:

Couldn't find any spots showing voltage.

Strange, there is always, always some small readings of a few Volts, so i would venture a guess at measuring at the wrong places, although there are no right places, but still, one lead from DVM to electronic/control ground or zero, be it Mesa board and/or power supply "negative" side, the other on grounds on power supply, case if metal, wire shield, etc.
And you will have to find a DVM with memory or use a scope to check the mains voltage when the plasma triggers.

PCW wrote:

Does sound like an EMI issue.

Have you tried debouncing the limit switch signals?
 ( This can be done with the hal debounce component or with some
hardware, a hal parameter )

This seems the most likely problem and a simple solution. I did go through your Hal and ini files shared earlier and could not see anything obvious wrong.

I probably wouldn't add a max limit signal if I was sharing a single home/limit switch but I don't think that will make any difference. Are you using proximity sensors or switches? normally open or closed? if prox sensors, are they pnp or npn?

I'll get the EMI power line filter tomorrow and hopefully have it all back up and running over the weekend. Will also go over all the grounding wires to make sure nothing has come off (what i'm thinking as this has slowly crept in).

Thanks for all your support and ideas to get me back on track.