FINALLY got it working well, all but the Pendant. Got the EStop to work on it but didn't get the rest configured yet.
Movement is repeatable to the tenth. X-12", Y-9", Z-7".
Had to put 3ph EMI filter on output of the VFD to get rid of spindle noise. I didn't use a shielded cable to the spindle.
THEN MACH4 CRASHES AGAIN!!! No doubt compatibility issues with CNC4PC ESS file and mach4 versions. Even built another computer. I've tried EVERY combo, I'm done with MACH with this old hardware.
Removed all the CNC4PC hardware and built a Acorn system from Arturo. All is good and solid once we figured out I had a bad C86 CNC4PC board. Had it all tuned and running in a day.
Been struggling with the other system for over 2 months 14/7!
Over $1000 of hardware not used anymore but I got no issues and it cost $400 for the cure.