[geomagnet]

Hello,

I've owned my PCNC for a few months and I'm starting to get the hang of it...but it's now behaving unreliable.

I have been prototyping impellers out of aluminum, but started to have accuracy issues so I switched to PVC to save $ and time. Now the accuracy
is even worse but appears to be isolated to the "Z-axis" motion. If I zero out
it's Z coordinate and run my g-code in air (or through plastic) then re-measure my true position, the Z coordinate is off between .08" and .2". Not to mention the part is scrapped.

I've called tormach and they sent me a new driver card, but that made no difference. I slowed the feed down to 6ipm and was able to hear the tone of
the stepper as it was travelling actually "hiccup". Thinking a motor was bad, I switched the leads between the "z" and "a" axis so that the "a" motor responded to the "z" signals and it too began to make the hiccup sound.

I've went through my computer and turned off EVERYTHING that is not need to run the machine. I re-installed Mach2 and checked all the settings. Everything is as it should be...however I continue to have problems. Especially if I leave the room, I'm guaranteed a tool crash.

FYI- I'm using Rhino4.0 and MadCam4.0 to generate the toolpath. As mention Mach2 is the controller.

Does anyone have any suggestions as to how I can get this machine working accurately?