I have had this happen. If I am understanding you correctly it is not your fault or the post processor. It has to do with the way the control interprets tiny arc moves.
This seems to be more common with the Fanuc 0-M control.
You want to change your filter settings to 1:1 and I *think* you'll see some improvement by tweaking the minimum arc length in the control definition...
Ask your reseller for help with this. Hopefully somebody else can shed a bit more light on this...
When this happened to me I had the error in a Fanuc 0-M and then took the exact same g-code and ran it successfully in a newer Fanuc (16-M i think...).


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