Hi Craig. Well, I am the guy with the hair of a wire inserting 230vac into my system. So popped everything.
The machine was working but I wanted more speed, so when purchasing more drivers etc I upgraded. The closed loop steppers gave that speed without losing steps, its just they are inaccurate, but inaccurate with the same difference exactly whether its over 500mm or in the case of a job that went bad a hour operation (wasnt watching).
I guess I need to reclarify, these steppers are not losing steps. This I say because they are exactly the same, every time. Almost like the resolution settings are out. But I have set the resolution to what it should be. And even changed it to get the same incorrect results. 2000 steps, 5mm pitch, 400 steps per mm. Or, 1600 steps, 5mm pitch, 320 steps per mm. But I am getting something like 320 steps per 0.99998mm (guess) or in the case of 2000steps, 400 steps per 0.99998mm.
Now I could work out the proper maths to change the settings to get this setup perfect, but it just seems wrong to change the parameters from factory to suit the needs if you know what I mean. Something is not happy. And thought someone here may have the solution. If I need to I will go back to open loop steppers.