@dc42 I will replace the servo drive with one from a different manufacturer. Thank you for your time and help!

@dc42 Ok, I take that to mean that I should look at the servo drive causing the behavior, right?

@dc42 maxreps is typically this now:
MaxReps: 4, StepErrors: 0, LaErrors: 0, FreeDm: 231, MinFreeDm 120, MaxWait: 721129289ms, Underruns: 0, 0

@dc42 No more crashes. But I still have the staircase behavior. It has only happened on travel moves, but I don't know if that is a coincidence with them being faster and longer moves. Is there any easy way of finding out whether the Duet is sending the pulses out as bunches?

@dc42 I am happy to report that this seems to have fixed my problems. Gonna do a few more test prints, but so far I think it's solved.

Thanks for the help!

@dc42 Note sure what the timing parameters are they need, but I do know that I can put scaling parameters in for the steps. Adjusting those so that I get 100 steps/mm should be easy.

Will report back here. Thanks for the help!

@3dpmicro Yeah. Linear motors with 1 micron or better feedback on the X and Y. They can also move wickedly fast....
https://www.youtube.com/watch?v=lq-wMWWwWzQ

@dc42 here the results:

M92
Steps/mm: X: 1000.000, Y: 5120.000, Z: 5120.000, E: 2400.000:2400.000:420.000:420.000:420.000:420.000:420.000:420.000:420.000

M560 is not set in config.g

MaxReps: 115137, StepErrors: 0, LaErrors: 0, FreeDm: 240, MinFreeDm 216, MaxWait: 788103523ms, Underruns: 0, 18

One more update: I just had it happen when pressing the "run mesh grid compensation button":

M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 2.0(RTOS)beta2 running on Duet WiFi 1.02 or later
Board ID: 08DGM-95BNL-MGPSN-6J1FD-3S86L-K1XZX
Used output buffers: 3 of 20 (9 max)
=== RTOS ===
Static ram: 28484
Dynamic ram: 95992 of which 0 recycled
Exception stack ram used: 324
Never used ram: 6272
Task NETWORK ready, free stack 476
Task HEAT blocked, free stack 1204
Task MAIN running, free stack 3864
=== Platform ===
Last reset 00:00:53 ago, cause: software
Last software reset at 2018-04-27 10:48, reason: Watchdog timeout, spinning module Platform, available RAM 5756 bytes (slot 2)
Software reset code 0x4050 HFSR 0x00000000, CFSR 0x00000000, ICSR 0x1441f014, BFAR 0xe000ed38, SP 0x2001ff24
Stack: 00415c41 00415b4c 61000027 00039884 00000000 0000000e 2000be18 00000004 a5a5a5a5 00000000 a5a5a5a5 a5a5a5a5 a5a5a5a5 a5a5a5a5 00435e97 00000001 20008618 00000000 ffffffe1 00000001 20006460 10000000 00000001 00000101
Error status: 0
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 0.0ms
MCU temperature: min 38.4, current 40.9, max 42.0
Supply voltage: min 24.3, current 24.4, max 24.6, under voltage events: 0, over voltage events: 0
Driver 0: standstill, SG min/max not available
Driver 1: standstill, SG min/max not available
Driver 2: standstill, SG min/max not available
Driver 3: standstill, SG min/max not available
Driver 4: standstill, SG min/max not available
Date/time: 2018-04-27 10:53:32
Slowest main loop (seconds): 0.004124; fastest: 0.000067
=== Move ===
MaxReps: 0, StepErrors: 0, LaErrors: 0, FreeDm: 240, MinFreeDm 240, MaxWait: 0ms, Underruns: 0, 0
Scheduled moves: 0, completed moves: 0
Bed compensation in use: mesh
Bed probe heights: 0.000 0.000 0.000 0.000 0.000
=== Heat ===
Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Segments left: 0
Stack records: 1 allocated, 0 in use
Movement lock held by null
http is idle in state(s) 0
telnet is idle in state(s) 0
file is idle in state(s) 0
serial is idle in state(s) 0
aux is idle in state(s) 0
daemon is idle in state(s) 0
queue is idle in state(s) 0
autopause is idle in state(s) 0
Code queue is empty.
=== Network ===
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0) Telnet(0)
HTTP sessions: 1 of 8

• WiFi -
  Network state is running
  WiFi module is connected to access point
  Failed messages: pending 0, notready 0, noresp 0
  WiFi firmware version 1.21
  WiFi MAC address 2c:3a:e8:0b:16:3b
  WiFi Vcc 3.34, reset reason Turned on by main processor
  WiFi flash size 4194304, free heap 17264
  WiFi IP address 172.30.1.30
  WiFi signal strength -65dBm, reconnections 0, sleep mode modem
  Socket states: 0 0 0 0 0 0 0 0
  === Expansion ===

@dc42 Ok, here is the log right after reboot due to failure. Watchdog timeout:

M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 2.0(RTOS)beta2 running on Duet WiFi 1.02 or later
Board ID: 08DGM-95BNL-MGPSN-6J1FD-3S86L-K1XZX
Used output buffers: 1 of 20 (10 max)
=== RTOS ===
Static ram: 28484
Dynamic ram: 95992 of which 0 recycled
Exception stack ram used: 324
Never used ram: 6272
Task NETWORK ready, free stack 476
Task HEAT blocked, free stack 1204
Task MAIN running, free stack 3800
=== Platform ===
Last reset 00:00:43 ago, cause: software
Last software reset at 2018-04-27 06:57, reason: Watchdog timeout, spinning module Platform, available RAM 5652 bytes (slot 0)
Software reset code 0x4050 HFSR 0x00000000, CFSR 0x00000000, ICSR 0x1441f014, BFAR 0xe000ed38, SP 0x2001febc
Stack: 00000007 00416748 81000027 fffeace0 00000000 00000000 00415c41 00435f08 21005027 00415b0a 61000027 2000ca30 fffffff1 00000000 00000000 00000000 200130b0 2000ca30 200088da ffffffff 20013738 20013b00 00000000 2000c900
Error status: 0
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 0.0ms
MCU temperature: min 38.3, current 40.8, max 41.8
Supply voltage: min 24.3, current 24.4, max 24.7, under voltage events: 0, over voltage events: 0
Driver 0: standstill, SG min/max not available
Driver 1: standstill, SG min/max not available
Driver 2: standstill, SG min/max not available
Driver 3: standstill, SG min/max not available
Driver 4: standstill, SG min/max not available
Date/time: 2018-04-27 06:58:46
Slowest main loop (seconds): 0.004691; fastest: 0.000068
=== Move ===
MaxReps: 0, StepErrors: 0, LaErrors: 0, FreeDm: 240, MinFreeDm 240, MaxWait: 0ms, Underruns: 0, 0
Scheduled moves: 0, completed moves: 0
Bed compensation in use: mesh
Bed probe heights: 0.000 0.000 0.000 0.000 0.000
=== Heat ===
Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Segments left: 0
Stack records: 1 allocated, 0 in use
Movement lock held by null
http is idle in state(s) 0
telnet is idle in state(s) 0
file is idle in state(s) 0
serial is idle in state(s) 0
aux is idle in state(s) 0
daemon is idle in state(s) 0
queue is idle in state(s) 0
autopause is idle in state(s) 0
Code queue is empty.
=== Network ===
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0) Telnet(0)
HTTP sessions: 1 of 8

• WiFi -
  Network state is running
  WiFi module is connected to access point
  Failed messages: pending 0, notready 0, noresp 0
  WiFi firmware version 1.21
  WiFi MAC address 2c:3a:e8:0b:16:3b
  WiFi Vcc 3.34, reset reason Turned on by main processor
  WiFi flash size 4194304, free heap 17184
  WiFi IP address 172.30.1.15
  WiFi signal strength -71dBm, reconnections 0, sleep mode modem
  Socket states: 0 0 0 0 0 0 0 0
  === Expansion ===