Aaron,

  If you are using feed override at any percentage, it can sometimes 
affect your rapids, it. the rapid speed is also overridden, exceeding 
the machine's capabilities.

  Run some handwritten g code tests.

  g0 x10 f1
  g0 x0 f1
  g0 x10 f2
  g0 x0 f2

  I use inches, so adjust your values.

  And so on, until you get a failure. Try each axis and then pairs.

  I noticed your power supplies are wired in parallel. Does it 
explicitly state in the docs that you can do that?

  A useful test would be to split the supply and wire one to the X and 
one to the Y.

  I have had lots of weirdo problems from power supplies not giving 
enough juice. Everything works fine until you do a multi axis move and 
the power supply can't deliver the watts.

  Did you isolate the logic signals from the power wiring?

  Dan





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