Random E-Stops in the middle of running G-Code

While running G-Code multiple “encoder read” errors come up,
so far the solution has been.

  • Unplug the control board
  • plug it back in
  • calibrate (retract all /extend all)
  • run updated G-code from last fail point
  • pray

is this really an encoder problem or is it something else? ive swapped out the Ethernet cables but that didn’t seam to help, and the position of the encoder fault changes every time.

( of note, there was a dust collection system set up but that has been removed)

Serial Messages
Index.html Version: 0.84
[MSG:INFO: Channel auto report interval set to 50 ms]
[MSG:INFO: FluidNC v0.83 (Maslow-Main-39543985-dirty)]
[MSG:INFO: Compiled with ESP32 SDK:v4.4.7-dirty]
[MSG:INFO: Local filesystem type is littlefs]
[MSG:INFO: Configuration file:maslow.yaml]
[MSG:INFO: Machine Maslow S3 Board]
[MSG:INFO: Board Maslow]
[MSG:INFO: UART1 Tx:gpio.1 Rx:gpio.2 RTS:NO_PIN Baud:115200]
[MSG:INFO: SPI SCK:gpio.12 MOSI:gpio.11 MISO:gpio.13]
[MSG:INFO: SD Card cs_pin:gpio.10 detect:NO_PIN freq:8000000]
[MSG:INFO: Stepping:Timed Pulse:4us Dsbl Delay:0us Dir Delay:0us Idle Delay:240ms]
[MSG:INFO: Axis count 3]
[MSG:INFO: Axis X (-2438.400,0.000)]
[MSG:INFO: Motor0]
[MSG:INFO: Axis Y (-1219.200,0.000)]
[MSG:INFO: Motor0]
[MSG:INFO: Axis Z (-100.000,0.000)]
[MSG:INFO: Motor0]
[MSG:INFO: tmc_2209 UART1 Addr:0 Step:gpio.15 Dir:gpio.16 Disable:NO_PIN R:0.110]
[MSG:INFO: Motor1]
[MSG:INFO: tmc_2209 UART1 Addr:1 Step:gpio.46 Dir:gpio.38 Disable:NO_PIN R:0.110]
[MSG:INFO: Z Axis driver test passed]
[MSG:INFO: Z2 Axis driver test passed]
[MSG:INFO: Kinematic system: Cartesian]
[MSG:INFO: Using spindle NoSpindle]
[MSG:INFO: Connecting to STA SSID:******************]
[MSG:INFO: Connecting.]
[MSG:INFO: Connecting…]
[MSG:INFO: Connected - IP is 192.168.1.64]
[MSG:INFO: WiFi on]
[MSG:INFO: Start mDNS with hostname:http://maslow.local/]
[MSG:INFO: SSDP Started]
[MSG:INFO: HTTP started on port 80]
[MSG:INFO: Telnet started on port 23]
[MSG:INFO: Caution: Unlocked]
Jog: Z1
Jog: Z1
Jog: Z1
Jog: Z1
Jog: Z1
Jog: Z1
Jog: Z1
Jog: Z1
[MSG:INFO: Set to comply]
[MSG:WARN: Encoder read failure on Bottom Left]
[MSG:WARN: Bad connection on Bottom Left encoder, failed to read 4 times in the last second]
[MSG:WARN: Encoder read failure on Bottom Left]
[MSG:WARN: Bad connection on Bottom Left encoder, failed to read 1 times in the last second]
[MSG:WARN: Encoder read failure on Top Right]
[MSG:WARN: Bad connection on Top Right encoder, failed to read 2 times in the last second]
[MSG:WARN: Bad connection on Top Right encoder, failed to read 27 times in the last second]
[MSG:INFO: Retracting all belts]
[MSG:WARN: Encoder read failure on Bottom Left]
[MSG:WARN: Bad connection on Bottom Left encoder, failed to read 1 times in the last second]
[MSG:INFO: Bottom Left pulled tight with offset -1554.596]
[MSG:INFO: Bottom Right pulled tight with offset -1607.460]
[MSG:INFO: Top Left pulled tight with offset -1611.025]
[MSG:INFO: Top Right pulled tight with offset -1664.061]
[MSG:INFO: Extending all belts]
[MSG:WARN: Encoder read failure on Top Right]
[MSG:WARN: Bad connection on Top Right encoder, failed to read 1 times in the last second]
[MSG:WARN: Encoder read failure on Bottom Right]
[MSG:WARN: Bad connection on Bottom Right encoder, failed to read 1 times in the last second]
[MSG:INFO: All belts extended to center position]
[MSG:INFO: Measured waypoint 0]
[MSG:INFO: Center point deviation: TL: 0.372 TR: 0.220 BL: 0.801 BR: -0.372]
[MSG:INFO: Center point deviation: TL: 0.372 TR: 0.220 BL: 0.801 BR: -0.372]
[MSG:INFO: Center point deviation within 15.000mm, your coordinate system is accurate]
Jog: Z-1
Jog: Z-1
Jog: Z-1
Jog: Z1
Home pos set for: Z
[G54:0.000,0.000,72.450]
[MSG:WARN: Encoder read failure on Bottom Left]
[MSG:WARN: Bad connection on Bottom Left encoder, failed to read 1 times in the last second]
[MSG:INFO: Tool No: 1]
[MSG:WARN: Encoder read failure on Top Right]
[MSG:WARN: Bad connection on Top Right encoder, failed to read 3 times in the last second]
[MSG:WARN: Bad connection on Top Right encoder, failed to read 27 times in the last second]
[MSG:INFO: Reset during file job at line: 148]
[MSG:ERR: Emergency stop. Update function not being called enough.1002ms since last call]

Evon wrote:

While running G-Code multiple “encoder read” errors come up,
so far the solution has been.

  • Unplug the control board
  • plug it back in
  • calibrate (retract all /extend all)
  • run updated G-code from last fail point
  • pray

is this really an encoder problem or is it something else? ive swapped out the Ethernet cables but that didn’t seam to help, and the position of the encoder fault changes every time.

the current fix for this seems to be to hot glue the ethernet cables in place.

David Lang

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