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Hi Mark,I watched you re-grease the spindle on Youtube. I don't have much luck there as most of my post are removed in a few seconds. I haven't figured why.But I noticed your bespoke hand wheel. On mine it is held on with an off the shelf detent. Easy and neat.
David 

Do the motors have tachos on them and what voltage do they output?
Encoder incremental 1Vss does not seem right, should be TTL level normally so 5V or more.
1Vss is ok for resolvers although they can do more...
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Scour ebay.de for Kolmorgen, those can be found for good prices although last i looked was probably two years ago.
But you do need to have the above info correct before jumping in.

I made a sim from your config and after lots of testing I was unable to replicate the issue.
It should be noted that I did not test pendant, ohmic, or step boost, I commented these out and also replaced my_Plasma.hal with sim_no_stepgen.tcl which is the standard QtPlasmaC sim hal file. I am only able to test in a sim as I have no hardware. If you can replicate it in a sim then could you post the sim and the workflow that causes it.

I did note that in showstopper.ini the relationship between the MAX_VELOCITY and MAX_ACCELERATION settings for the X, Y, and A axes and  their corresponding joints are incorrect.
 

I've forgotten the exact debugmsg at that time. I obtained the information for this issue from the diagnostic LED provided by the manufacturer. The specific content is: Invalid parameters were written.

After some extensive googling  and some back and forth with some Servo+drive manufacturers we are still searching for Motors and drives. In the mean time we striped everything of the machine and we found that the installed Servos were smaller than the ones specified in the schematics.
All the servos are the same ,Heidenhain QSY96G which have 1,4Kw and a moment of inertia of 6,3kg*cm2..I have found similar servos but with about 25% less moment of inertia. Does this influence noticeably the acceleration/deceleration ramps ?
Another thing that I found out is that servo motors, annoyingly, don’t use the NEMA sizes .It’s like the potatoes in an organic food store, everyone a different size.
I am gonna put here the specs of the QSY96G servos maybe someone can help me find suitable Drives .
power 1,4Kw
voltage 291V
current 3,3A
torque 3Nm
max current 25A
max torque 22Nm
moment of inertia 6,3kg*cm2
encoder incremental 1Vss




 

I had to check that:) The quote