Unfortunately, the Stepper Online drives we are using don't have that type of functionality. You would need Torque Control on the Stepper Drives like the torque loop on an industrial Servo Drives i.e. you reduce the Holding Torque via Torque Control analogue input and then you could move the joint with just enough torque to allow for re-positioning but not collapse. Then, your position loop would also have to be disabled to prevent position or following errors.

I encountered the exact same with my J1 -> J3. Simply place a ceramic cap (4.7nF worked fine) across one encoder channels on each axis to ground. You essentially create a low pass filter to ground. The Encoder trace on the scope is a LOT cleaner and the encoder drift stopped. Not a single false pulse on the Encoder Test program. Ideally you would want to put a cap across each of the two channels but I didn't see the point since my problem was solved. I opened the encoder housing on J2 and there's heaps of space to solder a small capacitor in there, I might end up doing that to tidy up the controls.

Hi, I've just converted my AR4 to. a MK2, I had a 24VDC/7.5A power supply on hand so I decided to give it a try. It's worked well so far. I have also piggy backed the Pneumatic valve from the same supply, just installed some protection across the coil to suppress the back EMF.  I checked the current draw while doing a Homing Cycle with the Pneumatic gripped energised and it was only drawing 5.3A.

Legend, thanks mate. I'm really chomping at the bit to get this robot going and I didn't know if I could get it anywhere else sooner. Clearly not. Thanks again