RESOLVED: X-Axis Showing Incorrect Travel After Stepper Resolution Upgrade (Elite Foreman, X-50)

Machines (Original/PRO) Troubleshooting (X35/X50)
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:hammer_and_wrench: RESOLVED: X-Axis Showing Incorrect Travel After Stepper Resolution Upgrade (Elite Foreman, X-50)

Hey folks — just wanted to share this in case anyone else hits the same wall I did.

Issue:
After updating to firmware v5.10 and following Onefinity’s instructions to upgrade my stepper motor resolution from 400 to 2000 steps/rev, I ran into a persistent problem:

My X-axis was reporting way less movement than it actually made (e.g., jogged 12", screen said 2.28").
Y-axis was working fine.

What I did (and triple-checked):

  • Followed the updated service bulletin from Onefinity
  • Changed the dip switches on all motors (X, Y, etc.) to the correct 2000 steps/rev config
  • Loaded the correct factory default .htg files via USB
  • Set Distance per Rev correctly (0.62992" for my X-50 rails)
  • Rebooted through Masso’s UI after every change
  • Even used the “Distance per Rev Wizard” to test

But the X-axis movement was still way off.

:magnifying_glass_tilted_left: The Fix:

Turns out the final problem was this:

:red_exclamation_mark:Masso does not fully apply changes to step resolution or motor control timing unless you physically power-cycle the machine — a soft reboot isn’t enough.

But there was one more thing:
Before that final power cycle, I decided to press down a little harder on the X-axis dip switches, even though they looked like they were in the correct position.

That must have done it — after the power cycle and re-setting Distance per Rev to 0.62992", everything worked perfectly. X-axis now matches actual movement and matches the screen readout.

:white_check_mark: Pro Tips If You Run Into This:

  • Make sure you firmly press the dip switches — sometimes they look set but don’t fully engage
  • After updating config files or distance per rev, power the controller off completely, not just reboot
  • Use a Sharpie mark on the screw + nut to verify real rotation vs expected travel
  • The 2000 steps/rev setting must match your physical driver switch settings, or Masso’s scaling will be way off

Hope this saves someone else the 3 days of head-scratching I went through.
Shoutout to @OnefinityCNC and to ChatGPT for helping decode what was going on.

— Cody

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