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SpringKing:
You did not say so, but I have to assume that you are operating in DNC, drip mode.
If you have a 1 meg memory and initially this is filled up from RS232 before you start machining, then you might run 20 minutes before you drain this memory. 19.2 kbaud is almost certainly not fast enough to keep up with machining short strokes. Most 1995 machines are limited to 38.4 kbaud, but that is better than 19.2. Newer machines starting around 1996 have 115.2 kbaud capability. If running in drip mode remove all un-necessary CNC programs.
You should use 7 data bits, even parity, and 1 stop bit.
If you have a lot of start stops of the servos, then regenerative braking may raise your DC voltage on the power supply capacitors an excessive amount. You may be able to reduce this problem by changing the transformer taps so that your steady state DC voltage is on the low limit side rather than the high side.
If you slow your feed rate so that you are never starved for data from RS232, then you may eliminate your over voltage condition. This will eliminate the constant start stops.
Over-voltage does not relate to carbon dust from the brushes, but yes it is important to keep the carbon dust cleaned out of the motors. HAAS has some specification like --- the shunt resistance from motor brushes to ground should not be less than 1 megohm. I am not sure what the exact specification is, but it is some high value.
Slowing feed rate is a means to reduce the data starvation problem.
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