I have finally got to the point on my lathe where I can start tuning. 
The setup is:
Mesa 5i20 driving a 7i29 with 1024CPR encoders on the screws. The PWM 
gain is set so the velocity is roughly equal to the commanded input. For 
example a PID output of 60 will give about 60mm/sec movement.

I have the P and D set up to be just under the oscillation point and 
following error is fairly low. Adding I increases stiffness when the 
machine is stationary but also increases the following error when 
moving. Even more strangely, the following error keeps increasing on 
long moves. It is almost as if I is working the wrong way round while 
moving. If I turn down I, the following error while moving is much less 
and it does not increase on long moves. Adding FF1 also increases the 
following error. So far the best results so far are with P=1200, D=10, 
everything else 0. Has anyone got any idea what is going on here?

Les

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