Hmmm. Might pay to check that all your drive gears/cogs are all tight. There isn't much that will throw off a circle except loose components, stretch of the belt from broken internal tension strands or binding from misalignment. I have some gears and belt here that has about 5 thou slop in them from brand new. Now I only use TDH circular profile belts as they seem to be the best for anti-backlash.
Have you done the test for the pulses per mm. The developers have got this working now and is pretty easy to use. It's next to where you type in the pulses in the section where you need to input the password to be able to access it. It's a small blank square that you click on and you type in the amount you wanted to move then measure it and type in how far it actually moved and the program will set the pulses for the axis. Easier to do than to write about.
Keep at it.....
Richard.
P.S. As an aside note, We had a small problem with our electrical connection over the past week or so and I got the suppliers around today to check it out. We were getting an electric shock off the metal parts in the shower when the heater was on.
I got a bit worried about that and after the electricians finished testing the power lines today they found out the neutral line had completely burnt off at the pole causing the electricity to go down to earth. We had 20 volts and 9 amps in the water pipe system and they said if it wasn't for the earth being connected to the pipes and earth stake we would have had full potential of 240 volts through us. I have residual current devices on all my boards and sub boards but that won't work if the positive doesn't go to earth. No wonder the power was pretty crappy. Not a good thing being wet in a shower and having electricity running through you. Probably the worst place in the house for it to happen. LOL
We're still alive. I can't die until we get you sorted out.....

Rich.