Hi Tman,
I have seen this error, too. It happens sometimes when switching from continuous mode to single step at just the wrong moment. I suppose it would be some kind of a buffering error, because the exact same program will run fine if run only in continuous or only in single step.
What is your camsoft FANUCARC setting in your card.ini file?
What factors do you have in nextmove, slowdown and blend, also found in the card.ini file?
Have you tried some very simple hand made code in the cnc?
Post your G00, G01, G02 and G03 logic here for a looksee.
You should be using a decelstop command in your G00 to prevent feedrate movements from being fed into the motion controller before the machine has reached position after the rapid move.
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