I have a motor issue where I startup my machine by powering up my box (PMDX-126 with the usual Nema 34 package from CNC Router Parts) and everything powers up great and talks to the computer but the motors automatically disable themselves. If I am to turn the power off on my Nema case which powers everything down on the machine side and power it up right away again - the motors will then work for the majority of the day. If you listen to the resistance of the motors when they engage they make a loud pop (not loud enough for me to be concerned about wear) on their first engagement when I initialy power up. On my second power up (because I do this idiot carnival ride every day now) they make a much softer engagement tone and then they work flawlessly.
All of this seems to point me in the direction of a faulty ground, something is grounded out, ground loop... Ground ground ground. Does anyone else have something savvy for me to try??? So far I have replaced the PMDX board that connects all my geko drives to the PMDX 126 - I have wired them manually twice, and replaced the wiring since with another PMDX board to see if my wiring was bad. All to no avail. I am wondering if there is some sort of static build up and it is discharging on startup - thus the loud engagement sound. Then on second startup it works because there is no static. Does this sound right? Also, how would I fix this? Considering Earth ground and all that - I'm smoked for ideas right now other than running a separate ground rod for the machine itself.