Stepper stall

I have a really hard time to get configuration dialed in for my CNC. It is getting better and better, but I am still see to many "random" stepper stalls which destroys my jobs.

I have recently with great success updated the base period maximum jitter to 25000, which is a bit above the ~21000 that I could measure. And better than the previous configuration of 20000.

I also set to StepTime/StepSpace/DirectionHold/DirectionSetup to a safe 20 000, which did a great difference. I was able to get way better speeds and acceleration and actually it was hard, impossible i thought, to stall the machine.

All axis are configured with 55mm/s and 200 mm/s^2.

There was a stall in an g0, so i have dropped the max speed to ~ 2000mm/s in Axis.

However I am a bit bewildered because I got a stall loosing steps on the z-axis and now I able to trigger it consistently by running stepconfs back and forth for approx less than 1min and then the stepper start to stall on almost all moves. It does not feel hot neither does the stepper driver, nor the nut on the trapezoidal screw. Does anybody have a good idea as to what that could be? And how i can configure the system to avoid it?

And in general what can I do to make sure that my configuration does not cause a weird stall after X hours of machining? Torture tests?


Mechanics:
www.cnc1.eu/en/kompas-h1000-kit.htm CNC with trapezoidal lead screws
Steppers
Wantai 57BYGH115-003B
StepperDrivers:
DQ542MA
Random Chinese BOB via LPT

can you add your ini and hal so we see what is in there
you may need to set the jitter to 50000
the Driver setting is
DIRSETUP = 15000
DIRHOLD = 10000
STEPLEN = 5000
STEPSPACE = 5000

This steppers do not rotate above 120U/sec your setting is 315U/sec
so reduce to
VEL=30
ACC =120
then it shoudt run with no errors

If you have the motors stay cold, i would guess that you are not on the optimal current point, probably you are low.
And your drivers, do they get hot? Do you run them with high enoug voltage?
Is your supply "hard" enough to determine liver enough current at good voltage.
And is your cabling alltime ok, no short interupts.

P. S.
I ask you also your motor / driver choice seems to be ok

Thank you!

I tried entering the values in stepconf.

But the Z axis stalled out again. I could run it at 20mm/s for some time without seeing any errors so for now it will stay there.. (there is a watercooled 2.2kw spindle on it, and that is a bit heavy).

However I cannot understand how it stalls out, it appears as overheating, but the motors does not feel (really) hot.

I have attached my configuration files. (the microsteps seems off but it matches travel distance, but the z-axis should have no microstepping? 400steps/rev in driver pins)

I run a very overpowered PSU with 48 V (rated at 78Amps)

The motors do get hot, but touchable and not burning.

I would never run a 50V rated driver with 48V. Too narow. I'm not sure if your driver does a overvoltage protection. And if your are breaking, how high is your voltage. If it is a switched psu, do you have some capacitance added anyhow.

Its a switched psu, and it may be narrow and but I am hoping/betting that its ok.
I do not have any extra capicitance (its like this www.taiwantrade.com/product/fuji-power-s...51-5681-1066548.html) I am just assuming that it is able to deliver.

hmm i tried running the zaxis 18 mm/s and 120 mm/s^s, back and forth continuously.

Still after 5 minutes it stalls out. But the time before it start to "overheat"/"overload" is increasing. So it must be possible to decrease to a safe point.

Ivm only guessing but would concebtrate on the DQ542MA.. I downloaded a manual, but i don't know if this is only a copy, or your driver a copy of...
In this not very narrative manual driver is described to have an overvoltage protection. But i see only one led, and no description of blink modes etc..
Can you see something on the controller when stalling

Not sure, but aren't there some holes with adjust-potentiometers. I believe to see something below the handle. Then i woud try to go for 45V to see if something changes