I would suggest the likely culprit is the direction line going to the driver. Put a voltmeter on it and see if it toggles as you command the axis forward and reverse.
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I would suggest the likely culprit is the direction line going to the driver. Put a voltmeter on it and see if it toggles as you command the axis forward and reverse.
Ok, I'm happy to report back that I made major improvement... it was the darn acceleration settings. This is a bit embarrassing but the controller is a new English version of an older metric unit and the metric settings were still programmed in there so it was accelerating about 25.4x as fast as it should!
(I guess if it could happen to NASA getting to Mars...)
Dropped the linear and curve acceleration values down and now it seems to work exactly as it should. Very smooth 800 ipm rapids with nice accel and decel at all ends of travel.
Sheesh- what a relief!
Now onto getting it running with my laptop, ESS, & BOB so I can run it off Mach3 as well as the pendant.
As another update <hope the room isn't empty>... things running smoother but still having some uncommanded Z-axis down movements, especially around the home position. I think I have a lead though after talking to a UK guru on this controller. I'm cutting the resolution from the driver down by half to see if that helps. Having too high of resolution apparently may be causing the Z-axis to get confused (highly technical term I know) during certain instances and since the Z-axis is vertical the weight causes the stepper to choose the easiest direction which is down.
Hopefully this fixes things for good. <cross fingers>