I have a Torchmate 4X4 GS. Generally it works fine. However, the X axis is always double the entered value. So all circles become ovals and a 5" X axis cut are 10" long. All X axis measurements are double what they are suppose to be. I fix this by setting X axis a 50% in Setup and it works OK. Anyone have an idea why it's doing this?
Definitely sounds like a gear ratio issue. Have you measured movement and adjusted for ratio variance? I had to make significant changes to mine. Here's a link to the setup process. http://torchmate.com/news/60/121/Initial-Configuration-for-Torchmate-Driver-Software-Version-3
See the screen shots below of a 4x4 setup file, depending on how your connect your motor cables will determine what axis controls what motor. Here I have X axis as the single motor and the Y as the double motors (the side rails), the X axis (single motor) uses a larger machine screw and thus one rotation equals 1 inch as you can see in the Drive Parameters screen shot (Step Mode is 4 with both Gear Ratio and Thread Count as 1). The Y axis (two motors, one on each rail) uses a smaller lead screw with a drive belt, results in two rotations for one inch, where the parameters screen shows Step Mode of 2 with GR of 1 and TC of 2. In your case if the X axis is doing two rotations for one inch then you will need to change it to one rotation for one inch, change your Step Mode to 4 with both GR and TC of 1.