On Friday 26 April 2013 17:13:24 Andy Howell did opine:

> Hello,
> 
>       After upgrading from 2.4.6(?) to 2.5.2, I'm getting a following 
error
> on my Z axis. This is a open loop stepper setup. The only way I could
> fix this is by setting MIN_FERROR=1. Previously is was 0.01.
> 
> The SCALE for Z is twice that of X and Y. I tried reducing the
> MAX_VELOCITY from 2.5 to 1.0, but that didn't seem to help.
> 
> I'm using the Gecko 540 controller.
> 
> I noticed that the sample Gecko_540B3.hal dirHold and dirSetup are much
> different from my config:
> 
> setp stepgen.2.position-scale [AXIS_2]SCALE
> setp stepgen.2.steplen 1
> setp stepgen.2.stepspace 0
> setp stepgen.2.dirhold 15200
> setp stepgen.2.dirsetup 15200

If this code is actually in effect, I see 3 potential problems.  stepspace 
= 0 s/b an illegal setting, and if the backspace move goes too fast to 
leave a space, BOOM.

Then unless your opto-isolation is done with CDS cells, the dirhold & 
dirsetup are both quite large unless your don't have the reset timing set 
in the parport loadrt and setp lines.  In that case the reset timing 
matches the BASE_THREAD period as each state will be one BASE_THREAD in 
duration.  So the above figures don't seem to grok at all well to me.

> My .hal has:
> 
> setp stepgen.2.position-scale [AXIS_2]SCALE
> setp stepgen.2.steplen 1
> setp stepgen.2.stepspace 1
> setp stepgen.2.dirhold 2
> setp stepgen.2.dirsetup 1
Much more reasonable. IIRC the unit value is in microseconds
> 
> Any idea why the behavior changed with the upgrade?
> 
> I tested the latency again, and that is fine. Its less than 3000.
> 
> [EMCMOT]
> EMCMOT = motmod
> COMM_TIMEOUT = 1.0
> COMM_WAIT = 0.010
> BASE_PERIOD = 35000
> SERVO_PERIOD = 1000000
> 
> X and Y axis are configured the same and works fine:
> [AXIS_1]
> TYPE = LINEAR
> HOME = 0.0
> MAX_VELOCITY = 2.5
> MAX_ACCELERATION = 10.0
> STEPGEN_MAXACCEL = 20.0
> SCALE = -10000.0
> FERROR = 0.05
> MIN_FERROR = 0.01
> MIN_LIMIT = -0.1
> MAX_LIMIT = 4.700
> HOME_OFFSET = -0.1
> HOME_SEARCH_VEL = -0.050000
> HOME_LATCH_VEL = -0.025000
> HOME_IGNORE_LIMITS = YES
> BACKLASH=0.0115
> 
> Z Axis - I had to make MIN_FERROR much larger. Changed from 0.01 to 1.
> [AXIS_2]
> TYPE = LINEAR
> HOME = 0.0
> MAX_VELOCITY = 1.0
> MAX_ACCELERATION = 10.0
> STEPGEN_MAXACCEL = 20.0
> SCALE = -20000.0
> FERROR = 0.05
> MIN_FERROR = 1
> MIN_LIMIT = -10.200
> MAX_LIMIT = 0.10
> HOME_OFFSET = 0.1000
> HOME_SEARCH_VEL = 0.050000
> HOME_LATCH_VEL = 0.025000
> HOME_IGNORE_LIMITS = YES
> BACKLASH=0.0005

You have a ball screw in Z only?  My acme screw BACKLASH with twin nuts to 
adjust backlash is more like .005" with a bit of wear, .0035" at best.
 
> I set this up long ago, so I'm likely forgetting something :(

So am I :)
 
> Thanks,
> 
>       Andy
> 
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Cheers, Gene
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