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Last two days it's been much better, thank you SGD.

That is a loooong post, thank you.

Sind die servos analog oder step/dir ?
Wen geld kein problem ist, nem das von Mesa:
7i96S - 5 step/dir venig IO, spindle mit encoder
7i83 - analog ausgange fuhr analog +-10V servos - nur wen diene servos analog eingang habben
7i85 - 4 encoder eingange und 4 sserial
wen mehr IO braughs
7i70 - 48 eingange uber sserial
7i71 - 48 ausgange uber sserial
oder nur
7i84 - 32 eingange und 16 ausgange
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das ist die beste combo fuhr ale moglihkeiten, und kan finden im Deutchland sein beim www.welectron.com
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Normaleweise wen finden an, die 7i95T ist ales beim eine platte fuhr step/dir und encoder, und die 7i97T ist AIO fuhr die analog servo und encoder.

Moved to "EtherCAT" section.
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From what i read here, EtherCAT has issues with position feedback to the point i was convinced it is useless, but i might be wrong or something might have improved by now.
Since i have no experience with it, i will retreat, for now.

Does the diagnostic software still communicate with the drive?

Any luck with this?
And you do not mention if it is running LinuxCNC, from your writing it seems it is not.

What exact errors are you getting?
Attach the pictures/logs here so we can have a look.

Hallo.
Was gibt?

Attach the hal and ini files here so we can have a look.

@geebee
Make a new config, start over.

Welche servodrives hast du genau ?

Gruß bassti

You have:

FF1 = 0

in your ini file

This should always be 1

LinuxCNC is very good at pointing out failures, so if you are not getting latency warnings while using it, it is not a latency issue.
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When i replied about the low current, i was going to add that to much current can also do that, but it has to be way over the rated motor current to cause such issues.
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In general,
-if the motor gets warm in 3 minutes, or hot in 5 minutes of being on = way to much current
-if it gets hot in 15-30 minutes = all should be good
-warm is if you can keep your palm on the motor
-hot is when you can keep your finger on it, but not the palm
-to hot is if you skin remains on the motor = the motor is cooked
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keep in mind that current ratings on cheap drives are "peak", while on good expensive drives it is "RMS", but lately cheap drives have both ratings written on them, so use the "peak" values while testing, then decide if you need to add more current if the motor skips.
Always use lower current if not sure.

The stepper motor withstands temperatures of 120 degrees Celsius.
This is, of course, the maximum parameter and during normal operation it should be cooler.
On the other hand, if the motor is cold, it means that the current is too low, resulting in less shaft torque.
Without a thermometer, this can be assessed by stating that the engine should be hot, but should be able to be touched by hand.

Sörry for eventually annoying anyone. Some reading I certainly did, it is just a lot of stuff. I have used several motors both of the same and different types and two different drivers. I can limit current at the tb6600 and certainly did. The cs-d508 does not provide any switch to do so. Its datasheet mentions overvoltage and overcurrent protection. Apparently the current nevertheless is too high, not too low. The motors heat up quickly when not moving. I lost a second one even though I have become more careful after the first one burned. I certainly do know how to wire a 2 phase stepper. Mistakes might happen, but I will not repeat them every time I reconnect the stuff. I have been working with steppers and arduino but not yet on a professional basis.

So at the moment, I suggest its more likely a latency issue. It is gonna take me a while to go through the stuff pcw has told me. After that, I will let you know what I did and what were the results.

Cheers