1st time setting up.. whats normal..

[EddyCurrent]

(At this stage I have no idea how the Shaft rotation marries up with distance moved but I am sure that will become apparent.)

You need to use the 'Steps Per' setting in the Mach3 motor tuning pages. this link explains the calculation; http://www.mycncuk.com/threads/7733-...0877#post60877

When I start the RR the 4th motor does the Vibration jig which is worrying as there is no DRO movement.

It may actually be responding to the G-code but looks like vibration. Edit: sorry just noticed you said no DRO motion, looks like it's not responding to G code then

When I try to restart the program all (not Y) start a whining noise.. prior to the program continuing.. Is that normal?

To a certain extent, mine sounded like whales singing at first until I got the tuning right.

As much as I am unfamiliar with Stepper motors, the heat that seems to be being generated even when not running the GCode seems excessive.. Too hot to touch after a few minutes..

Some people say this is normal, I don't know for certain, but mine don't get that hot.

I assume I could use Channel 4 instead of Y with a bit of re-routing..?

I was going to suggest that at first but thought you might already have a motor connected to it, yes try that.

One final question.. On the set-up (Foxtech you linked..) it shows specific Numbers in specific boxes when setting up the Ports and Pins Motor Output, Input Signals and Output signals.. I have taken these on screen No.s as the Correct No.s to insert as I have no other list of No.s to refer to.. (Unless I get something useful back from Longs..)

The numbers in the boxes have to match the setup of your machine, the ones in the manual could be correct or they may just be examples.

Watch these videos to learn about where the numbers come from.