This is what I have right now (pretty much stock out of pncconf with some minor experimentation changes):
Code:
# Axis Z
#********************
[AXIS_2]
TYPE = LINEAR
HOME = 0.0
FERROR = 5
MIN_FERROR = 0.5
MAX_VELOCITY = 1.0
MAX_ACCELERATION = 30.0
P = 50.0
I = 0.0
D = 0.0
FF0 = 0.0
FF1 = 1.0
FF2 = 0.0
BIAS = 0.0684
DEADBAND = 5.0
MAX_OUTPUT = 0.0
ENCODER_SCALE = -20000.0
OUTPUT_SCALE = -10.0
OUTPUT_MIN_LIMIT = -10.0
OUTPUT_MAX_LIMIT = 10.0
MIN_LIMIT = -0.001
MAX_LIMIT = 6.0
HOME_OFFSET = 0.000000
HOME_SEARCH_VEL = 0.016667
HOME_LATCH_VEL = -0.016667
HOME_FINAL_VEL = 0.016667
HOME_USE_INDEX = YES
HOME_IGNORE_LIMITS = YES
HOME_SEQUENCE = 0
I've tried FERROR of 5.0 but I seem to be getting a lot of "joint 2 following error" faults.

I also drift. That isn't so surprising because I haven't tuned yet, although that process is a bit of a mystery for me still.
I am ignoring the Y axis count problem for the time being. I just pulled the 7i77 encoder input until I have a better handle on everything.
Q: while I'm playing around with Calibration, are the limits being used?
[on edit: Yes, limits seem to be working (not completely validated... might just be the software limits on travel... TBD) but there is an odd experience with them that I'll have to figure out at some point. When I hit a limit, I can't move the axis at all. I'd expect that I couldn't move *further* into the limit condition, but I should be able to move away from it. That is the only way to clear the thing.]