Just an update today (tuesday). We still have not resolved the problem. I went ahead and sent an email into support at cross the roads electronic with more specific details. However I wanted to update everyone that was interested in what we have done for troubleshooting.
Tonight we:
1. Removed the MA3 Analog Encoders, because there was something happening to the Slave Talon SRX to become out of sync with the master that we did not understand. So we put back in the US Digital S5-1000 encoder, and change the sensor type from Analog Encoder back to Digital Encoder, and the Slave problem went away. We went back to having a super SMOOTH PID closed loop control, except the sensor counts are not repeatable.
2. Removed the US Digital S5-1000 encoder and replaced them with some older GrayHill 61K-128 CPR encoders. We re-tuned our PID and got the same super SMOOTH closed loop control. However still losing counts.
3. I brought the FLUKE O-Scope home and wanted to prove there was nothing wrong with the encoders we have. Can someone else review a couple of these videos? I don't see anything that pops out here at me that is abnormal? We have QTY (4) US-Digital S5-1000 and QTY (2) Grayhill 61K-128. All six videos are here:
https://www.dropbox.com/sh/yha32m2df...kUVZG16Aa?dl=0
4. Finally what we decided to was disable the robot and only watch the "Sensor value" from the Get Status VI block. We manually moved our carriage by hand after marking a spot on the elevator. The sensor position would not repeat in this case even when in disabled state. We emailed this video and our code to Cross Roads.
Tomorrow what we plan on doing are these things.
1. Removing the sensor from the gear box, and manually turning the shaft and seeing what the values are to the Talon SRX. We will document this via video as well.
2. Re-wiring the sensor direct to the Robo-rio just as Mr. Anderson suggested.
The closed loop control works amazing in the Talon SRX, if we can just figure out this "repeatability" problem....ugh....so frustrating that we are so close with the Talons SRX...
Is there anyone else out there that has a working closed loop controls with the Talon SRX with an encoder with no position issues?