OK...just a follow up. My first test was with no computer connected...just trying to get the singing started. Also...this CNC system had a distinctly loud singing prior to the conversion so i don't think it's just too quiet to hear. Since the singing pitch is probably defined by the encoders, I would expect it to sound different, but not completely silent. I'm using USdigital SMS500 500 line encoders. I'm using sheilded wire (grounded at one side only), but it's running inside the same 3/4" flex conduit as the motor wires
Since then, I decided to go ahead and connect the computer and see if I could make some motion happen (and perhaps see an improved motor action). Well, it moves, but not very well. It appears to be very jumpy like a stepper motor when skipping. Even when just holding a single direction.
Are these normal symptoms of a Gecko/mach setup that's just not tuned? It seems too out of whack to be just poorly tuned. My attempts to adjust it didn't seem to improve things much.
Right now I've tested it with current limit turned to full but it seems like it's just not getting enough power. If the limit is below halfway it will trip the fault. I did meter the motor supply while it's going and changing directions to confirm that it's not losing power, but it's holding a strong 80vdc no matter what action the motor is taking.