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Don,
can you post a photo of the tool height setter so we can see it? Have you checked if you can unplug the THS cable from the controller and can you unplug the cable from the THS switch? This...

Chances are it is.!! . . But You'll know soon has you start cutting. . It gums up the cutter and gives a really bad finish if the feeds and speeds are not perfect.
When you have it wrong it tends...

Bloody hell no wonder it got hot at 7.5mtr/min thats miles too fast for cutting Ali with a 4 flute cuttter. Wouldn't go much above 2.5mtr/min.!! Actually I wouldn't be using a 4 flute cutter full...

assuming your going to use a brush to clear the chips, plenty of WD40 and at a speed you can keep the chips clear
some alli will soon clog and snap your tool if you dont keep it clear

i tend to...

For 4th axis CNC-toolkit can do anything:

http://www.cnc-toolkit.com/

Unlike most CAM programs it's not just pushing a few buttons to get the result, you do have to do a bit more work but in...

Don,
hopefully the photo will let us see where the coil connections are going to get an idea of whats happening. I just noticed the power cube driving the cooling fan, classic. You might want to...

Don, can you post a photo looking down into the control box showing the top down view of the relay, contactor and the power supply. Also what is on the front panel of the control box? It looks like...

It sounds like the contactor and relay aren't getting activated.

Can you trace the wiring, to see what the relay and contactor coils are connected to?
I'd guess they're somehow connected to the...

EStop is a good one to check as are the LEDs and actual voltages. Also check all limit and home switches.

It would be unlucky to have blown all four drivers but the lack of a second clunk does...

Just a quick thought -- you have reset the emergency stop button!!

Peter

From the control box picture the top right are the main stepper motor drives, they look something like the 542 or 752.

If so then it looks like only the step and direction are connected, and the...

Have a google fr Corian, great stuff for routing.

It does not make a difference. Since the flow rate is reasonably high, once the system has reached equilibrium the temperature of the water at any point in the system will be virtually the...