On Tue, 2 Feb 2016, Marius Alksnys wrote:

> Date: Tue, 2 Feb 2016 20:40:21 +0200
> From: Marius Alksnys <marius.alks...@gmail.com>
> Reply-To: "Enhanced Machine Controller (EMC)"
>     <emc-users@lists.sourceforge.net>
> To: emc-users@lists.sourceforge.net
> Subject: [Emc-users] 7i43 encoder count failures
> 
> Today I catched the fault which was causing headache for quite a long
> time already.
>
> There is a machine with one 7i43 P (200k) and one 7i39 and one BLDC
> motor with encoder. I got reports about unexpected moves of the machine
> while standing still.
>
> Today I saw:
> count 712171
> rawcounts 780979
>
> changing to:
> 679403
> 748211 accordingly
>
> which is exactly 32768 or 0x8000 while motor is off and dead still.
>
> Together with that I saw huge number of errors (dmesg output):
> hm2/hm2_7i43.0: Encoder 0: quadrature count errorhm2/hm2_7i43.0: Encoder
> 0: quadrature count errorhm2/hm2_7i43.0: Encoder 0: quadrature count
> errorhm2/hm2_7i43.0: Encoder 0: quadrature count errorhm2/hm2_7i43.0:
> Encoder 0: quadrature count errorhm2/hm2_7i43.0: Encoder 0: quadrature
> count errorhm2/hm2_7i43.0: Encoder 0: quadrature count
> errorhm2/hm2_7i43.0: Encoder 0: quadrature count errorhm2/hm2_7i43.0:
> Encoder 0: quadrature count error...
>
> I will code some more safety features to prevent dangerous
> consequencies. I will try different ports - I can swap 50pin headers and
> swap 7i39 channels. There are 4 of them in total.
>
> And this is replaced 7i43 board after first one I diagnosed as working
> only when warmed and put on the shelf. It had issues with EPP
> communications as far as I remember. The motherboard is the same.
>
> What might be there, anyway?
>

Sounds like errors in the EPP connection. I would try shortening the
EPP cable to the minimum length (If you are using a flat cable) or
if you need a longer cable, use a IEEE-1284 compatible cable
and a very short flat cable adapter to the 7I43s header. Might also be a 
marginal EPP port on the Motherboard.


Peter Wallace
Mesa Electronics

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