Another servo tuning

Just to make life easier we had massive storm and power outage. It never ends.

I have tried increasing decreasing FF1 and FF2 and 1 and 0 is about as good as it gets with changing D I can only make it worse.

I am wondering if it is not some kind of system noise because it is very squigly while it is on in steady motion. Could there be a problem with the motor driver? I am feeding it step dir instead the usual +-10v

This is just a thought I am guessing that Peter could shine some light on this.
Would it be better if I reconfigure drives for lets say PWM dir?

I could not use the original Bosch servo drives and the first try was with small cheap drivers which ony had Step Dir but the new once I have can be set into different types of inputs.

I have drives set in position control too.

Could any of these cause these issues?

correction: can only set it to PWM 50% zero set point not PWM dir
 

I would try open loop step/dir first to eliminate possible mechanical
or encoder issues (take feedback from stepgen position rather than
encoder position)

I will give it a go tomorrow but I have the same issue on all three axis so I am thinking I have some sort of systemic error somewhere.

I am having brain storm day and guys I just discovered an issue I think, maybe not related to the tuning maybe it is.
The machine came with Heidenhain LS403 scales and I am using EXE 610 to convert it.
I just went through the datasheets again and the max input frequency to the EXE is 50Khz, with linear scale grating 20um and if I am calculating right is 1000 mm/s.
It looks like I will have to look for faster EXE boxes.
Anyone knows of any faster exe boxes if I am understanding the datasheet correct?

I actually have no idea what they do if the f is too high. I have been thinking about testing it but have no idea how. I have been having fairly decent accuracy but all up to 1000mm/s I just started with speed and accel increase lately with not much luck so far.
What I am about to test is to bump up accel but limit the speed to 1000mm/s and another test to run open loop as Peter suggested.
How do I measure ferror in open loop? do I have to create a script to calculate motor fb - encoder pos? or what would be the best way.
I am guessing that ferror in open loop config will be always 0, is this correct assumption? since there is no actual encoder feedback.

So this is what happens if I bump up accel to 300 and limit the speed to 16 m/min in hal

here is the openloop net x-pos-fb     <= hm2_7i95.0.stepgen.00.position-fb
but I don't know how the ferror is calculated in this case I had to decrease scale it 2m now otherwise I could not trigger.

Edit: I forgot to bump up the max speed again

is there any way to reload HAL without closing and opening whole thing again?

and open loop with
MAX_VELOCITY = 100.0
MAX_ACCELERATION = 300.0

at 3000mm/s and 6000mm/s 
now since I don't know where the ferror comes from in this case I kind of have no idea what this measurement tells me. I guess I would be happy if this was actual encoder to cmd difference.