I've dug a bit deeper, looking again at the RSGS manual.
First off, the instructions for modifying a servo are disturbingly vague about how to do it and how to verify that you've got it right. I suspect that some users
will have it wired wrong. What is clear, though, is that two wires is fine - they are using "ground and wiper", so what they feed to the servo is what the servo would expect to see - a voltage varying from 0-1V (or whatever). There can't be any ground issue there - but that voltage could be causing radiated EMI, though I doubt that it would be strong enough to be causing these kinds of issues. Nevertheless, the first thing I'd do myself would be to modify the supplied harness to extract the pins from the one end or the other, split all the paralleled wires, twist them in their respective sets and reassemble.
In the original software the Gains tab gave access to "Position Gain" and "Velocity Gain" but the new version (1.6) has only "Position Gain". What we don't know is whether they just removed access to the "Velocity Gain" (i.e. its value is hard-coded in the firmware) or they re-worked the algorithm to combine it into a new parameter (whilst still calling it "Position Gain"). Unfortunately "Velocity Gain" is probably a misapplied term here - I suspect this is the Integral (I) gain and what they call "Position Gain" is the Proportional (P) gain. It's likely the processor
is running "PI" controller, i.e. no "D" - makes sense.
Forgive me for not reading back over this entire thread to check, but (using the latest firmware/software) can you stop the jitter by dialling down the gain? On a "P" only controller, the classical method of tuning would be to increase P until oscillation occurs then reduce P to half that value. On a PI controller, you'd now increase I to correct the steady-state error (the difference between the target setpoint and the achieved setpoint).
I see, too, on the 1.6 software that there is a Monitor tab - can someone confirm if this works and what is it giving feedback on? If it's active, it might give some clues as to what is varying when the system is oscillating.
The "cross talk" between Roll and Pitch channels
could indicate a "bug" in the firmware. It's entirely possible that the roll and pitch channels are in some way connected within the mathematics - the RSGS is mounted
on the pitch axis, so it must be deriving discrete values for the pitch and roll attitude from a compound movement. When you disconnect one of the axes from the RSGS it will know that there's an open connection on that axis, i.e. the inputs to the algorithm may change in such a way that the system instability (oscillation) will not occur (for the
current P gain). Does this happen for
any P gain setting? Most interesting, though, is your revelation that the instability will re-occur
without any disturbing input once you reconnect the second channel. This suggests that it's an Integral (I) term issue in the algorithm - the Integral is the sum of errors over time: if the algorithm is seeing system noise in a steady-state system (and backlash in an active system) as valid errors then they will, indeed, accumulate over time and force the servo to react. Again, it would be interesting to see if different P gains affect the time-to-onset of this oscillation and/or it's frequency/magnitude.
Just fishing around here, in the hope that something I say
may trigger a Eureka moment with somebody who a) has one of thee things in front of them and b) understands more about system controllers than I do.