I recently the Pulsar (stepper version) and tried to hook up my previous 4" home made 4th axis, using a new Leadshine driver just like whats in the machine.

I tuned the 4th in Mach using the steps/unit calibrator in it works perfectly in both directions.

But when I use the jog keys, it only sometimes responds. Sometimes it only responds in one direction.

And then using the MDI commands it doesn't respond half the time, and doesn't seem to go the proper distance the other half the time.

Meanwhile it always works perfectly using the calibration steps/unit utility.

I don't hear any squealing from the stepper to indicate the accel/velocity is too fast. When it does work, it's nice and smooth.

I don't think any wires are loose as nothing moves it to change whether or not it works or not.

Any ideas? I'm thinking ESS issue, but not sure what to try?

Thanks!
Also here's my new enclosure I built (just showing off. . .)

Attachment 267636