g540 e stoping and crashing mach

[fragger6662000]

i have a g540 on a g0704 conversion and it works great when it works.

the issue is that the machine drops into e-stop or locks mach up. this makes the machine next to useless as it can happen once every ten minutes.

the setup i am using is a keiling kit with 3 x 3.5amp 480oz 23 motors and 1 980oz 35 motor. using a 48v 12.5amp switch power supply and connected to a smooth stepper.

The smooth stepper does not have an issue as the same system ran on my x1 setup with no issues.

There are three things that cause the system to sop working.
1. trun on the strip lights in the workshop.
2. slightly move the parallel cable.
3. it just randomly stops though the could be linked to 2 as the control is not vibration isolated.

things i have tried.

line filter on the ac input, (sorted out the hiss on the radio (result))
different cables.
ferrites on ac, pc etc (white bricks every where)
Power supply (tried unreg power supply using a tridodal transformer)
Cut the sheilding of the usb cable, caused the SS and mach to lock up.(was a SS recommendation)
New rear connectors from gecko.
Re flowing the joints on the parallel cable on the g540 still the same.

It appears that moving something on the g540 is causing a signal to be generated that knocks out the SS.

I am thinking it may require returning to the states.