The Dreaded X axis stepper error using UC400ETH and UCCNC !!!

[A_Camera]

What's the benefit of 200Khz?
50Khz gives you a longer pulse width, which can be a benefit with some drives.

...that depends on his settings, which I still have no idea about.

50kHz means maximum 50,000 pulses per second.

So, here is my calculation for my machine:

If a motor, like most steppers, takes 200 steps/rev, using 10x micro stepping means 2,000 step pulses for one rev. The speed is 9000 mm/min which is 150mm/s. To move 150mm with my 1605 I need to turn the screw 30 times, so 30 x 2000 = 60,000 which is obviously more than 50,000 meaning that my MINIMUM should be 100kHz.

In other words, it is not possible to say if 50kHz is enough or not, that depends on his speed, screw pitch and micro stepping settings, but those questions are not answered yet, or I missed that part.

The fact that he's had this issue with both Geckos and Leadshines, means it's probably not the drives.

That would point to maybe the power supply, an issue with accel/velocity settings, or a mechanical issue.

Yes, that could be the issue as well, but even the kernel frequency if it is too low, or in fact, the current settings. Of course, if the kernel frequency is too low then lowering speed and acceleration might hide the actual issue when the solution should actually be raising the frequency. If the current is too low then acceleration and deceleration may occasionally be a problem, while at other times it may work. Can also be that it works on one axis but not another. Of course, if the PSU is not able to deliver the necessary current then that might also be an issue...

You said the motors are very hot? What are the motor specs, and what do you have the drive current set at?

I don't think motor temperature is a problem. In fact, I think most people draw the wrong conclusion, put their hands on the motor and "decide" that it is too hot, when in reality, you can't really hold your hand on anything for a longer period which is above 40-50 C. Steppers can get as hot as 60-80C so I would really not worry about that, assuming the drivers are set up right and the motors are designed for that current. In any case, "motors too hot" says nothing without stating the MEASURED temperature.

I had similar issues once and the solution was simple: raised the motor current and the kernel frequency. Problem gone immediately after and never seen it again. Of course, motors got hotter but that doesn't matter, I measured and is still well below the limit.