Seeking and Destroying as ordered!!!
My next steps: I formatted the PC, installed XP pro, DMC-ST, connected (Note: my firmware was one revision out so updated that and reset my PID and BN). Installed Mach3 and Galil plugin, did not use my old XML (in case there was something wrong) Went thru and set up the Galil config and the Mach3 settings pages. Ran my 5" square 100s of times no error. Press stop and it is off every time in the axis that I hit stop.
For these tests the Galil, PC and Mach3 are connected to a known good production machine with good mechanical. Running a 5" square pattern in DMC-ST works great. In ST Pressing ST, AB, causing an OE all has zero position loss. In Mach3 position is lost every time I press stop, when I go back to DMC -ST the TP is off. I am 100% sure that pressing stop in the Mach3 is resetting the Machine Coordinates, I confirm this in DMC-ST by checking TP.
I note that when I press stop the machine decelerates violently. As a test I set the Mach3 AC/DC really soft so that it is nice and lazy around the corners (even rounds them), but when I press stop it really jerks hard, now this should not cause a Galil position loss but it is. I reviewed the Galil Plugin Log and note a ST then an AM, but see no indication of other cause. I also note the AC and DC are set to the default of 30,000,000, lowering this does makes the Stop smooth, but position is still lost (but by even more). Again with the Galil you can stop it with a sledge hammer and it still knows where it is thru any other software.
I have worked with Galil controllers for almost a decade now, I know they do not exhibit behavior like this, they are in my opinion the best controllers in the world! I know that many many people use Mach3 successfully with the Galil. Is there any setting that might be BNd into my controller that could cause this behavior?
Ahhh reviewing the log I think I found the cause!!! After I press stop this is the string of commands the Plugin is sending: ST, AM, CS S, CS T, ST, AM, "DP -8421, -19672, 0, 0" ***This DP is bad, the DP should Never Ever happen unless the user presses "Ref All Home". I can see on Steppers this may be desireable but on Servos it is not good. As you said Steve the Galil always knows where it is, Mach3 should never ever change that except after the home move. I never once pressed home in the attached log. I have attached the log for your review, so you can see what I am seeing. The only cause for this that I can think of is on the 1st page "Motor Options" (both are unchecked), 2nd page (all set to Servo). I am anxious to see what you find out.
Here is my Gcode just in case:
%
O0000
N100 G20
N102 G0 G17 G40 G49 G80 G90
N108 G0 G90 G54 X0 Y0 S8556
N116 G1 X0 Y-5 F300
N120 X-5 Y-5
N122 X-5 Y0
N124 X0 Y0
M30
%
I reduced it to this, still got out with a stop press:
%
O0000
N116 G1 X0 Y-5 F300
G4 P.1
N120 X-5 Y-5
G4 P.1
N122 X-5 Y0
G4 P.1
N124 X0 Y0
G4 P.1
M30
%
Highest regards, thank you for any help that can be provided.