I just upgraded to a G540 and a 48volt power supply. I had everything working fine before I upgraded with TB6560 boards and some cheap power supplys. The problem I am having now after upgrading to the high dollar stuff is, when I upload my simple test bracket into Mach 3 which worked before the G540, I click run and the gantry blasts off from the bottom left corner where I start and flys up to the top right corner and keeps on going and going and wont stop until I hit stop because it rams into the end of my table. On table display in mach I see it going to the part but I have to stop it before it gets to the part to cut or it will just ram into my table ends. I been messing with my soft limits for 4 hours cant figure it out. I am using the G540 XML provided from there website. The steps per in on the XML are at 20,000 which is incredible considering they were at like 1600 with the tb6560 chinese stuff I had hooked to it. Whats my problem?
Its a direct drive setup
Steel 14-1/2 Deg Pressure Angle Gear Rack 24 Pitch, 1/4" Face Width, 1/4" H O'all, 4' Length:
12 tooth gears on the motors
333 oz on X,Y 1.8 degree 200 step
425 oz on floating Z 1.8 degree 200 step
G540, 48 volt 7.3 amp supply

Table is approximatley 49"x49"
cheap dell dimensions running it.