John Figie

 But if it overshoots the
> commanded position and goes into reverse to bring the motor back by more
> than a 1 or 2 % drive while the motor is still coasting fwd, it will
> crowbar the psu, getting it hot instantly, causeing the psu to do a shut
> down until it has cooled for 2 or 3 minutes. Even then, no heat in the
> BTS IC's.
>

So if the motor is rotating forward and has enough inertia then when you
try to slow it or reverse
it it will become a generator and try to increase the output voltage on the
PSU. Is the
crowbar circuit in the PSU an overvoltage protection crowbar? If so, then
maybe that is the issue.
Maybe you need some way to get rid of the stopping energy with a shunt
resistor and switch that activates
before the crowbar trips.

In industrial motion systems a shunt resistor and switch is used to
regulate the DC bus that feeds
all of the servo axis. This is not a precise voltage regulator, it just
turns on the shunt as the voltage gets
above a set limit and then turns off again as the voltage returns to a
lower limit.

Regards,

John

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