Appreciate that. I did read your post. I have done all, if not, most of your suggestions. I took my time assembling when I got my unit. Was easy to do since everything came piece meal and took weeks before I had everything. The controller came first. Not that I am an expert, but I still build my own desktops (for graphics, video processing and stuff), so I am aware of the importance regarding seating connectors properly.
I ran a separate 20 amp circuit from the breaker box to feed the router and vacuum. The vacuum hose is grounded. Computer and controller are on the same circuit protected by a surge protector. I did all the suggestions I found in the forum regarding computer power settings etc., including running Easel on Chrome.
As I said, I’ve had these issues regardless of which router I ran. What I know is that the DeWalt I ran way too high (inexperience), especially in the beginning. It took a while, I want to say about 3 months, before I got into longer cuts. That’s when I first ran into this particular problem. Since I abused the DeWalt so much, the brushes wore out pretty quick, and I replaced them. Turned out that wasn’t it. Simply didn’t come back on. Factory sent me a new one, but I didn’t want to wait, hence a trip to the store and purchased the Makita. The Makita I never ran as high, between 1 and 2. Did a lot of reading here regarding cut settings etc.
Until I did this project. I wanted to speed up the roughing cut (1/4" bit, speed on the router set at I want to say 4.5 - 5.5, and increased the feed rate. Let it run and at about 25% XCarve stopped. I reset, let it run again, same thing. Reset, this time deceased router speed to 4 and adjusted feed rate. Ran to 72% this time and then stopped. Gave it 2 more tries, same thing. In the end, adjusted router down to 2, decreased feed. This time it ran through. You can imagine, at this point I had spent some significant time in the garage.
Anyhow, the detail pass was slated in VCarve to run for about 2.5 hours. After I made the necessary adjustments it took almost 4. But it ran through.
Sorry, it’s such a long story btw. Knowing what I knew now after all the fixes I applied (tried) I have come to the conclusion that this is not a power issue (in my case) due to the fact that the stoppages occurred at the same time depending on the router speed settings. That leaves me with the signal flow and subsequent interruption of it. At least that’s where I am at, at this point.
I may not need the powered USB hub at all. The reason I want to try it regardless, is because I am curious now and want to see if the XCarve stops at higher router speeds even with a hub. My experience (past and current) seem to point toward RF noise interference.
While I am not an expert, most of the things discussed in this forum regarding this issue are pretty logical and common sense. I certainly learned a lot more about this than I wanted to. There’s a lot of things going on when working with a computer, XCarve, Controller, and imported gcode, besides the usual stuff like dirty power, line overload and so on. Pinpointing a problem like this can be different from user to user in my opinion, because no setup is the same.
All one can do is start with the least expensive and work your way through step by step. For my part I appreciate the tips and guidance here. It helped a lot, and I learned a few other things along the way.