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« on: July 10, 2016, 06:55:08 AM »
Hello Rush,
What design error are you talking about? So far we have not yet determined if there is a design error or not.
A filter on the secondary AC power supply (after the transformer) could help reducing spikes and ripple on the AC. You have not answered my earlier question: what is the AC voltage on your drives? You need a multimeter set to AC and measure the power supply lines for your drives with the machine staic and with the machine running.
If you have access to a scope, you could see what how the power supply for the drivers looks like. Also the power supply for the USB card might need to be checked, this appears to have its own power supply on board so a clean AC input is desired although it appears the card has some capacitors on board. Checking this power supply might help also, a scope will tell you if you have a 'dirty' power supply or not.
Ground wiring is quite simple, every component needs to be grounded once and to one common point. Where this common point is or which part of the machine this is (could be the entire frame) is not important but there can only be one connection from the drives to this point. Since the drives do not have a separate ground wire, I assume the frame, or the metal enclosure I see in the picture is the ground and there is one wire from the metal frame to the yellow/green ground wire. All seems to be correct but is worth checking for lose or bad connections.
Shielded wires should have a ground connection only on one side of the wire, quite simple.
I would start with measuring the power supply lines to the drives and the USB card first. See what the AC voltage is and if you have a scope, see if they are clean.
The spindle drive is connected directly to the AC lines at 220V? (measure the voltage to be sure) If so, I would disconnect the spindle drive from the power supply lines and run the test again, this eliminates the spindle driver and spindle motor from the problem.
Let us know what you find.