Below is a copy of an email that I sent to our service guy tonight..If anyone has ANY ideas please help....Thanks in advance.


Regarding the status of the Mercury as of 10:33PM on Friday night....:
We did receive the Mainboard and Motor today, thanks. I did not have time to replace it at first and was going to do the replacement on Monday......until.....we received a pile of orders LATE this afternoon. I changed my mind and went back to the office at 6:00PM tonight to do the replacement.
First I changed the Mainboard, it did include the EPROM chips as we requested (thanks). When I powered up the first time the new board seemed to be more responsive than the other one so I said "OK now we should be good". After sending a few files we determined that the product was the same as before. NO NET RESULT
Second I decided to changed the motor, since it did show up there was no reason not to try it.
Upon inspection and taking pictures before making the replacement I determined that (1) of the motor mounting screws (the one in the round or "pivot" hole) was almost completely loose. At this point I said "OK case closed this is the problem, maybe I should just tighten everything and run a job". I then decided that as many times as we have been into this machine and since the new motor was laying right there, I would just replace it.
I replaced the motor including checking the pulley set screws in the adjacent wheel. Tensioned the drive belt just a little, put the cover back on and was SURE that this would fix the issue.
We ran the first job.....SAME PROBLEM as before. I ran several jobs from different software.....SAME PROBLEM. I adjusted the "tickle" or "trickle".....SAME PROBLEM. Moved the "tickle" back to the factory default....SAME PROBLEM.
I ran a few plates that I could send to someone....for review to see if you have any other ideas.
If you run something maybe 10 inches or so across the text on each end for about 2 inches looks perfect, the 6 inches or so in the middle almost looks "double printed" more so than the normal "ghosting" that you may see due to the "tickle" being a little off.
Reggie and I have both checked all of the mechanical things that we think could be even a little off.....rails, wheels, pulleys and belt tensions.
It almost looks as though the laser is just simply out of sync with the movement, but only in the middle of long X axis strokes.
We have tried running RAMP ON and RAMP OFF from the software side....SAME PROBLEM.
We CAN run jobs in a very small "cluster" mode with near perfect results, we just do not have the time to run LARGE jobs in "CLUSTER" mode.
I really need this machine running at FULL speed to meet my customer's demands....any ideas that you may have would be VERY much appreciated.

Thanks again for your service.

Best Regards,
William