TedBlack

I have reset the settings as you recommended.

Then I reprogrammed the Shapeoko settings.
I typed up a Notepad txt file to copy them over.
They are at the bottom of this post if anyone wants to shortcut and copy / paste straight into coolterm.

Source of Communication Error:
When I copied and pasted all four of the motor settings there was an error half way through communication with the TinyG. An error message come up because it received $2.r instead of $2tr. This happened a few times in random spots.
I have $ex=RTS/CTS and RTS/CTS selected in coolterm, however it didn’t seem enough. Then I enabled ‘DTR’ and ‘DTR ON’ in Coolterm and I could send large chunks of the settings below without any errors.
See Screenshot here:
http://www.gerardscientific.com.au/images/CoolTermSettings.png

This might explain why I had some erratic behavior when drawing arcs or sending large files. As I suspected the buffer in the AVR filled up and my Laptop just kept sending anyway as it can send much faster than the AVR can receive and process the G-code.

Settings:
The nan settings are now gone.
I’m getting feedback from the machine of it’s position as it moves around during a command.
The velocity_max now works. I can still change the feedrate to a value above the max, however it will only traverse at the velocity_max I have set for the axis.
Motor timeout doesn’t work after sending a file, however you said it would only work for 435.xx builds.
As for my settings buggering up from moving an axis manually. I doubt it. Find me someone who hasn’t done that. The output of the stepper drivers should be well isolated from the power supply and I wouldn’t suspect that. Even if the power was off the stepper driver would have a very high internal impedance and wouldn’t allow stepper EMF to feedback to the power supply to then power the atmel.

System Settings

$ja=2000000
$st=1
$mt=10

Motor Settings
Motor1,2,3,4

$1ma=0
$1sa=1.8
$1tr=40.00
$1mi=8
$1po=0
$1pm=0

$2ma=1
$2sa=1.8
$2tr=40.00
$2mi=8
$2po=0
$2pm=0

$3ma=1
$3sa=1.8
$3tr=40.00
$3mi=8
$3po=0
$3pm=0

$4ma=2
$4sa=1.8
$4tr=1.25
$4mi=4
$4po=0
$4pm=0

Axis Settings

X,y,z axis

$xam=1
$xvm=5000
$xfr=5000
$xtn=0
$xtm=220
$xjm=5000
$xjh=10000
$xjd=0.01
$xsn=1
$xsx=0
$xsv=3000
$xlv=100
$xlb=20
$xzb=3

$yam=1
$yvm=5000
$yfr=5000
$ytn=0
$ytm=220
$yjm=5000
$yjh=10000
$yjd=0.01
$ysn=1
$ysx=0
$ysv=3000
$ylv=100
$ylb=20
$yzb=3

$zam=1
$zvm=800
$zfr=800
$ztn=0
$ztm=100
$zjm=50
$zjh=1000
$zjd=0.01
$zsn=0
$zsx=1
$zsv=3000
$zlv=100
$zlb=20
$zzb=3

My motor config is as you mentioned above.

I still have three problems.

Can’t do a single arc using G2 X0 Y30 I0 J15
Gives a straight line 30mm along X-axis left to right.

Motor timeout not working on files:
I tried the flow control and my full circle generated by makercam works. 🙂
However, I have a 10 second inactivity timeout on my motors which normally works after a single command, but after sending a file some motors stay activated. (one time just the z-axis, another time all four motors)
I have even tried changing this to power down when idle on Motor1-4:
[1pm] m1 power management 1 [0=remain powered,1=power down when idle]
The thing still keeps all motors powered after sending a file
( but they now power down immediately after a single command).
The end of my file has an M5 and M30 command straight after the G-codes.
Problem still remains after removing these two commands….

Max_Velocity problem
I still have the problem of the max-velocity setting not working.
If I reduce max velocity on all motors to 1000 then I can still drive them at speeds of 16000!

Here is my $$ dump:
http://www.gerardscientific.com.au/Download/DoubleDollarDump.pdf
(Note this was before setting $ex = 2, $1pm =2 etc.)

This is my cool term settings: (is is correct?)
http://www.gerardscientific.com.au/images/Screenshot.png

John, I will try the chillipepper app when I have time

I am running the Stepper Drivers on TinyG.
This is my second Shapeoko and I have 4 x brand new Nema23 connected via 18Gauge wire directly to TinyG. Big 12V fan for cooling.
I communicate via CoolTerm. Standard Baud etc as you recommend in Github.
I’ve stayed away from all your other “beta” software.

Steppers are wired correctly. Besides if one coil was out of phase, or coil pairs were swapped it would just go in the wrong direction…

Current Setting:
If I increase the current above 10 O’clock then a G0 move will fail mid flight for X axis Motor 1.
I have 10:30am setting for the dual Y-Axis, Motor 2 & 3.
I believe I now have this as good as it gets.

I’ve tried performing an arc manually:
G2 X0 Y30 I0 J15 (a half circle, diameter 30mm, starting at bottom, end at top)
This draws me a vertical line upwards 30mm long. The Y-axis stepper lights blink away and the machine moves in a vertical straight line, however x-axis light does not come on during the move. Tried turning current up and down during the move and still no action from X-axis motor. Other arcs just give diagonal lines as mentioned and seem to have some moves stored in buffer memory and perform them on the next command.

Circle in MakerCam:
I have since drawn a 50mm circle in Makercam.com and it draws 7/8ths of a circle (yay) and then stops 🙁
Drew a bigger circle and generated new code, stops in exactly the same spot on the circle 😛 every time. Visually, code seems fine around the spot it stops! I checked the co-ordinates of the stop position and compared to G-code. I stops after a certain line of G-code. No errors found in the code before or after this spot!

Tried the Hello World from Shapeoko
Got through one letter I’m guessing ( I was drawing up in the air ) before the thing went spastic. It shot off real fast 100mm/4in (G0) in the Y direction and motors failed mid flight. So without the controlled deceleration it was one nasty stop when it failed. This move doesn’t appear in the G-Code, so not sure why it did it. :-/

Here are my settings:

Line number: 0
X position: 0.000 mm
Y position: 0.000 mm
Z position: 0.000 mm
A position: 0.000 deg
Feed rate: 0.000 mm/min
Velocity: 0.000 mm/min
Units: G21 – millimeter mode
Coordinate system: G53 – machine coordinate system
Distance mode: G91 – incremental distance mode
Feed rate mode: G94 – units-per-minute mode (i.e. feedrate mode)
Motion mode: G80 – cancel motion mode (none active)
Machine state: Ready
[fb] firmware build 412.01
[fv] firmware version 0.97
[hp] hardware platform 1.00
[hv] hardware version 8.00
[id] TinyG ID 2X2660-FYX
[ja] junction acceleration 2000000 mm
[ct] chordal tolerance nan mm
[sl] soft limit enable 0
[st] switch type 0 [0=NO,1=NC]
[mt] motor idle timeout 10.00 Sec
[ej] enable json mode 0 [0=text,1=JSON]
[jv] json verbosity 0 [0=silent,1=footer,2=messages,3=configs,4=linenum,5=verbose]
[js] json serialize style 0 [0=relaxed,1=strict]
[tv] text verbosity 0 [0=silent,1=verbose]
[qv] queue report verbosity 0 [0=off,1=single,2=triple]
[sv] status report verbosity 0 [0=off,1=filtered,2=verbose]
[si] status interval 0 ms
[ec] expand LF to CRLF on TX 0 [0=off,1=on]
[ee] enable echo 0 [0=off,1=on]
[ex] enable flow control 0 [0=off,1=XON/XOFF, 2=RTS/CTS]
[baud] USB baud rate 5 [1=9600,2=19200,3=38400,4=57600,5=115200,6=230400]
[net] network mode 0 [0=master]
[gpl] default gcode plane 0 [0=G17,1=G18,2=G19]
[gun] default gcode units mode 1 [0=G20,1=G21]
[gco] default gcode coord system 0 [1-6 (G54-G59)]
[gpa] default gcode path control 0 [0=G61,1=G61.1,2=G64]
[gdi] default gcode distance mode 1 [0=G90,1=G91]