I can offer something to look for, but no fix.

I have 2 G540 drivers, looks identical.
One is without problems.
The other very distincly stops stepping on the Y channel when the step 
rate goes below 150 Hz. (So a circle will have two flat spots)
This can be seen also when feeding with a lab type pulse generator.
I do not know why. The pulse timing I use is very conservative.
I have discussed this  problem with Gecko, the only solution is to send 
the drive for repair. (Shipping cost from Sweden easily buys me a new one)
I live with this, the faulty drive sits on a machine that only needs 
three stepper channels.



> Hi all;
>
> I thought I had this fixed.
>
> running a 4 hour engraving process, and the X axis slowly moves. At the
> end, it is off, maybe, 0.3mm or so. (using centre drill before and after,
> you can see different points)
>
> I thought I had this fixed, because I've had this problem for a long time,
> now I find that the error is small, but still exists.
>
> - 5i25 has stepdir, etc, parameters set to 2,000 (all 4 of them)
>
> - The G540 motor is tuned as per directions. (tuned more than once)
>
> - Only X axis affected, and only in 1 direction.
>
> - machine slowed down, currently trying one where I increased accel
> parameters to slow down any "jerking".
>
> I'm beginning to think that the G540 is not working quite right, as I've
> spent (probably, over the last year) about 1 week on fixing this X axis
> slip.
>
> What would you guys try?
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