Interrupted movement on X-Axis

You would not  allow for 2 phases. I make it 4 x 5 = 20 amps /1.4 = 14.3 amps required. You have heaps of power and 48v its a good voltage.
I would follow PCW's advice.
 

I went back and actually measured the current out of the Power Supply when it was running. Nowhere near maxing out the PS. more like maybe 1 amp total on all 4 motors when running above the stock. Not power limited...

This was with the stepper timing at and above what PCW suggested. That was at:
StepLen 5000, StepSpace 5000, DirHold 10000 and DirSetup 5000.

It is still missing/stalling/ messed up even at 20k, 20k, 20k, 20k.

I had worked to reduce latency and ended up with the histogram attached. This was overnight with 8 gears running. Except for a couple outliers, I figured it was good. Using 1,000,000 SERVO_PERIOD (set lower I was getting "error finishing read" issues)

Any other ideas you can point me to?

Attached are .hal and .ini as well.

Thanks again.
 

Set the drives to 3A and test again.

You might wan to read this, www.geckodrive.com/support/step-motor-basics.html , some really good info.

How have you wired the power to the steppers, one set of wires per driver from the PSU or some other method.

Thanks Rails, yes, I had read that doc. Re-read just to refresh. Wired with Star pattern, not daisy-chain. 
Tommy - Tried again at 3A and it still gets hung up. The test program is mainly x-axis moves, so that is what I see failing.

Yes, there is some friction in the setup. It is a toothed belt and pulley arrangement. It seems as though the motors are not generating the torque that they are capable of and pushing through. And this is just "cutting air", not 0.25" cut into aluminum or something... 3.0 Nm or 27 in-lbs should be enough.

I guess I'll try swapping the drivers between axis and re-test. 
Besides the settings on the drivers, is there another place the power to the motors can be limited? Motors are cold, not even warm when stalling.

If feels like I am just making a noob mistake, so hit me with the obvious.

Thanks, Tim

What drives?
Can you switch the X motor to another drive?
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Things to keep in mind:
-if a stepper motor is opened and the rotor pulled out = dead motor due to demagnetization,
-if at any time in it's life the motor has been driven with to much current, same thing as above, dead or very weak,
-if metal dust has gotten inside the motor or it was stored in humid places, rust will cause stalling and/or full block.
- some Gecko drives required step times of 15000, to long since i used them, some 500 !
--
if none of the above apply, then mechanical issues:
-check if the belts lay properly on the pulley all around it, not just partially,
-check for broken bearings or idlers, they cause intermittent stalls
-check pulleys for sticky dust/debris between teeth
-check for belt skipping
-no springs on belts to keep them tight, at high accelerations they will flex and cause skips