I'm not as inclined to let the TECO Westinghouse guys off the hook as you are. They are putting out a product that is designed to drive high RPM, 400 Hz motors. I may be inclined to give the techs a break, but not the company. The Huanyang manual had TONS more info on setting up the curves than TECO. With that having been said, let's see what they come back with. I am inclined to agree with you that the parameters I am using are sub-optimal.

I don't have a problem with open collector outputs. This design is used on millions of opto-couplers and comparators world wide. I got it available so I'll use it.

CF6-07-04 at $10.00/ft?? I agree it's the cat's ass of cabling and I would spec it for an industrial application; but for a home shop CNC there has to be something cheaper that will do the job. Beware of cables that use Cu-Al alloy. OK for crimpled connections, I guess; but not worth a damn if you have to solder connectors.