Full Motion Flight Simulator: P6 Mods

Full Motion Flight Simulator
P6 Mods - Safety

Any piece of machinery with moving parts that can potentially hit or even injure somebody must have a way of turning them off in case of an unexpected situation. The DOFReality platforms have an (optional) "EMERGENCY STOP" button for this. It is plugged into the control boxes and, when pressed, closes a circuit that powers a relay, which in turn cuts power to the motors. And here is where the problem lies: because this button is optional and therefore the control boxes also need to work without it, it can only "close" a circuit to tell the boxes to cut power. In order to function as a real safety feature, however, such a button must itself open a connection when pressed. There are several reasons for this:

The cable that goes from the button to the control box might get broken.
The plug might be pulled out of the box.
The button might be damaged and won't close the connection.
The relay might be broken and won't engage when powered.

Fortunately, there is an easy way to convert this into a real safety feature. All it takes is to swap some wires, as shown in the images below.

CAUTION: Make sure the control boxes are disconnected from main power before opening them!

The "EMERGENY STOP" stop button.

Open the button case and move the wires from the "NO" (Normally Open) to the "NC" (Normally Closed) position.
If the wires are already connected to the "NC" position in your button, there's nothing to do and you can stop here (close the button case, though).

Open the control box and locate the relay board. On the right side note the wire in the top position ("NC").

Move the wire from the top to the bottom position ("NO"). Repeat this for the other control box.
Close the button case and the control boxes and reattach all cables.

That's it! Now your platform will only move if all safety features are working.