So, my colleage and I did some more testing.
For the document library in question, we stopped sync on his PC. And from SharePoint we synced again. As suggested
The green sync icon does not appear on his machine, but the duplicates keep being created when I work in SharePoint and his machine is one.
--> so - stopping sync, and syncing down a fresh copy has no effect.
So, we tried the opposite. I synced down the doc library to my machine and he was the one working in Sharepoint
--> same result. There was not green sync icon on my machine, but it does sync. It also creates duplicates, however.
A few days ago, we tested other document libraries to provoke the error, but everything worked fine (and the green sync icon was on those folders).
So - today we took another of the libraries and synced to my machine also. So, one library in SharePoint synced to two local copies. What happened now is very strange. Without any of the files being edited (in SharePoint or by Excel, Word, whatever), new copies started to appear. In the root of the folder it made about 10 copies of each file there, and name them filename+ "-1", filename+ "-2". I hurried to stop syncing to my local machine and it stopped.
So - what have we learned:
- If we take a previously working document library from SharePoint and sync down locally, the problem will start there (no green icon, but sync happens). For document libraries where the sync was started months ago, no problem (and they have green icon)
- if we have 2 local syncs of a SharePoint document library, and we are online at same time, the sync will "go in circles" and create copies of files - even though the file is not currently worked on.
So - the combination of a recently synced document library and both of us being only creates copies when file is edited in SharePoint and one of us has a sync local. And it creates multiple copies if we both have the same folder synced down (even for files not being worked on).
very strange - any help is greatly appreciated.