joint 2 following error

Did you change the
DIRSETUP = 200000
line?

What are you drive specs?

I dont see how that can be anywhere near right

(there are probably only a couple step drives in the world with such
long setup/hold times, Old Parker/Compumotor drives come to mind)

If your PID adjusted with errors, you will get FERROR too.
If your P is too small. the error will occures.

aike wrote: If your PID adjusted with errors, you will get FERROR too.
If your P is too small. the error will occures.

This is a stepper system, I think. So no PID.

With a stepper system two things cause f-error

1) Stepgen velocity and stepgen accel not having enough "headroom" over the axis valuse
2) The base thread rate not actually being able to make all the requested pulses.

I am guessing 2 here. What is your base thread rate, and what is your max vel and scale?

After correcting the hal and ini velocity and accel values
the follow errors stoped with the exception of when a G33.1
is used. The problem appears to be due to sudden spindle
velocity changes during low RPMs tapping.

I am replacing the spindle motor with a real servo motor
this should produce a more uniform rotation of the spindle
and thus the Z axis should be less chalanged to follow
the spindel encoder.

Strangly the axis following error problem has returned even
though I have not changed any configuation values.

I serched the the ini and hal files for the Base period value
but did not find it.

Is this because I am using a Mesa 5i25 board and the
the base thread rate is not avalable in the ini or hal files?

I do remeber seeing in the Pncconf wizard setup a thread
period input value. Is this the base thread rate?

A base thread is not needed (or wanted) for the hardware stepgen.

Are the following errors during rigid tapping as before or just normal motion?

Did you fix the huge dir setup and hold times? (they were 200 uSec which has to be wrong)

Have you changed anything that would add more latency? (re-running the latency test might be a good idea)