[octothorp]

I feel like I've tried every possible combination of settings to get my Keling setup working, and I still get frequent stalling and grinding.

I've got:
C10 Parallel board
3 KL4030 drivers
3 KL23H2100-30-4B (382 oz) motors
KL-320-36 power supply

I've tried both setting each axis to 800 SPI with the microstepping set to 1, or 6400 SPI with microstepping set to 1/8. I've got the current set to 3.0. I've tried every possible combination of direction and step pulse. I get an almost passable accuracy when I set the speed really low (one inch per minute), but it still grinds roughly every 1/3 of a turn. At higher speeds, like 20 inches per minute, it will have longer smooth stretches, but the grinding and stalling will also last longer when it occurs. If I try a speed like 60, it stalls for almost the whole cycle.
This grinding and stalling occurs regardless of whether my motors are hooked up to the lead screws, or just running on their own. It happens with all 3 motors.
In trying to diagnose the problem, I've noticed that when I send a G0 command in Mach3 and then watch on the diagnostics screen, the buffer value is typically at 3%, but will shoot up to about 12% when the stalling occurs. Unfortunately, I don't have enough knowledge to understand what all of this means, and what I can do to fix it. Any suggestions would be greatly appreciated.

[elmerfud]

um, I think 382oz motors are rated at 2.5 amps?
the higher current setting would give the wrong 'chopping' effect, if it has any.
i think the 1/8 or 1/10 stepping would smooth it a little, less amps, more voltage, the motor tuning in mach 3 usually likes .3 microsecond points on the motortuning (.3off,.3on,.3off).
You could spend a whole evening trying the settings with the motor on a bench, you'll get it soon enough.

[jalessi]

[nomedia="http://www.youtube.com/watch?v=8Am69_F93yA"]YouTube- 65 ipm[/nomedia]

Do a search on stepper dampers.