Probe plus

Means the Probe is triggered even before it can start the probe. Either your bit is already touching the plate - or your machine has a short circuit somewhere grounding out the collet of the router (where the magnet attaches) providing an alternate path to GND that is not through the touchplate as expected.

Use the Troubleshooting Tab in CONTROL to check the probe status, then look for a short circuit between the collet and DC GND (often via a badly wired VFD spindle, a chaffed through wire touching the frame, or a limit switch installed without the rubber spacer)

 

Use the Troubleshooting tab in CONTROL to monitor the Probe status.

Perform some eliminative testing:
- magnet on spindle - triggered or not
- vfd unplugged - changes from triggered to off?
if not try
- other devices one-by-one unplugged until resolved
That way you can zoom in on the actual source of the problem, by playing the elimination game.

 

What is the "aviation plug" - what exactly do you have? not one of our machines? Is it our Probe or something 3rd party as well?

That's not where we expect a ground loop to form

Hard to say from the limited info posted so far, but use the Troubleshooting tab

1) VFD on, Magnet on collet - what does the PROBE pin say in Troubleshooting tab?
2) VFD off, Magnet on collet - what does the PROBE pin say in Troubleshooting tab?
3) VFD on, Magnet not on collet, rather place it on the probe plate in your hand - not touching the machine: what does the PROBE pin say in Troubleshooting tab?
3) VFD off, Magnet not on collet, rather place it on the probe plate in your hand - not touching the machine: what does the PROBE pin say in Troubleshooting tab?

 

Also see other questions (not answered yet)

Pin? How are you turning on the VFD? Using a control signal pin from the BlackBox, or manually. Also, define ON: just power to the VFD on, or properly ON as in spinning the spindle
How are you switching the VFD on/off power-wise - any switching mechanism (or operator unplugging mains plug) that also disconnects the Earth?

 

Ok so that part of it is OK. Mains plug has an earth, it goes into the VFD, and back out to the spindle body. That domain, is MAINS EARTH

The other equation is DC GND (sounds similar to earth, but keep the seperation in mind - ones for mains power, the other is the low voltage side GND)
Normally GND and EARTH does not (and should not for safety reasons) touch

The VFD is wired correctly, but something else in your system is connecting DC GND to AC earth, thus providing an unwanted return path for the probe signal via Mains Earth to this DC GND / Mains Earth short and thus back to DC GND to complete the circuit the probe would normally do to the GND on the Probe Plate.

The hunt is on on your end to find where this short happens. Again, elimination game, unplug DC stuff one at a time until the probe goes OFF with magnet on the collet
It "could" be a bad computer too

Refer to XYZ Probe Plus with VFDs and other ground-loop inducing components for some other scenarios - lengthy read, but worth reading the whole thread

 

AC Mains has its own EARTH (Ground rod outside house. Neutral bond in main panel, etc). Outside the US we call that Earth, but yes you might know it as "ground"
In contrast GND (DC ground. Usually negative pole of single rail PSU - is a separate domain entirely - don't mix mains systems and dc low voltages systems) is what the PROBE, Limits, etc uses (sig pin closing to GND via switch, probe, etc = triggered)

GND and EARTH should NEVER be electrically connected.

Somewhere in your set up, they seem to be.

Its not inside the VFD. So time to look elsewhere

 

Well done to you for finding that! That was not an easy hunt! Barely visible! Well done!