My encoder calibration is changing every time I run the offset routine. This is a new behavior…it’s preventing me from using the index to do quick start.
If I calibrate then things are fine. If I try to use the pre-configured position things run away.
It looks like I’m missing encoder counts…count_in_cpr is coming up different each time.
error = 0x0000 (int)
is_ready = True (bool)
index_found = True (bool)
shadow_count = 64067 (int)
count_in_cpr = 24067 (int)
interpolation = 0.5 (float)
phase = -0.41407108306884766 (float)
pos_estimate = 64067.765625 (float)
pos_cpr = 24067.7578125 (float)
hall_state = 2 (int)
vel_estimate = 0.0 (float)
config:
mode = 0 (int)
use_index = True (bool)
pre_calibrated = True (bool)
idx_search_speed = 10.0 (float)
cpr = 40000 (int)
offset = 87300 (int)
offset_float = 1.2214689254760742 (float)
bandwidth = 1000.0 (float)
calib_range = 0.019999999552965164 (float)
I’m not so sure this was an issue. I relaxed the encoder disk and was able to get consistent index starts and closed loop. 
Could be that the encoder was slipping on the shaft?
It’s definitely not slip…but I’ve seen a similar issue before. It loses counts from poor mounting or a warped disk I think.
I use US Digital encoders with 10,000CPR. They are two piece and are temperamental to mounting conditions.
Anyway…it’s sorted for now.