Endstop config prevents boot of Smoothieboard

We have tried everyhing, and have narrowed it down to the lines endstop.xmin.pin and endstop.ymin.pin. As soon as we set those lines in the config, the board refuses to boot and gets stuck with LED 1 and 4 lit, 2 and 3 dark, signalling a “firmware error” according to the docs. It is not a firmware error however, since the board works fine without the endstop config. We have also tried both new and old config syntax, assigning to different pins, commenting out other modules in case of a memory problem, but no luck…
We are using the CNC firmware usually, but we have tried both flavours.

The smoothieboard is a v1.0, used to drive a large (1600x3000mm) 100W chinese laser cutter, and is doing a great job so far, but we need some fixes available in the latest firmware to be “production ready”.

Any help is greatly appreciated!

Kind regards,
Mats-Ola

This is our config file:

# NOTE Lines must not exceed 132 characters
## Robot module configurations : general handling of movement G-codes and slicing into moves
arm_solution                                 cartesian        # 

default_feed_rate 10000 # Default rate ( mm/minute ) for G1/G2/G3 moves
default_seek_rate 30000 # Default rate ( mm/minute ) for G0 moves
mm_per_arc_segment 0.5 # Arcs are cut into segments ( lines ), this is the length for
# these segments. Smaller values mean more resolution,
# higher values mean faster computation
#mm_per_line_segment 5 # Lines can be cut into segments ( not usefull with cartesian
# coordinates robots ).

Arm solution configuration : Cartesian robot. Translates mm positions into stepper positions

alpha_steps_per_mm 139.058462958997222 # Steps per mm for alpha stepper
beta_steps_per_mm 69.426557463320214 # Steps per mm for beta stepper
#gamma_steps_per_mm 200 # Steps per mm for gamma stepper

Planner module configuration : Look-ahead and acceleration configuration

planner_queue_size 32 # DO NOT CHANGE THIS UNLESS YOU KNOW EXACTLY WHAT YOU ARE DOING
acceleration 700 # Acceleration in mm/second/second.
acceleration_ticks_per_second 1000 # Number of times per second the speed is updated
junction_deviation 0.05 # Similar to the old “max_jerk”, in millimeters
# Lower values mean being more careful, higher values means being
# faster and have more jerk
#minimum_planner_speed 0.0 # sets the minimum planner speed in mm/sec

Stepper module configuration

microseconds_per_step_pulse 1 # Duration of step pulses to stepper drivers, in microseconds
base_stepping_frequency 100000 # Base frequency for stepping

Cartesian axis speed limits

x_axis_max_speed 36000 # mm/min
y_axis_max_speed 36000 # mm/min
#z_axis_max_speed 30000 # mm/min

Stepper module pins ( ports, and pin numbers, appending “!” to the number will invert a pin )

alpha_step_pin 2.0o # Pin for alpha stepper step signal
alpha_dir_pin 0.5o! # Pin for alpha stepper direction
alpha_en_pin 0.4o # Pin for alpha enable pin
alpha_current 1.5 # X stepper motor current
alpha_max_rate 36000.0 # mm/min

beta_step_pin 2.1o # Pin for beta stepper step signal
beta_dir_pin 0.11o! # Pin for beta stepper direction
beta_en_pin 0.10o # Pin for beta enable
beta_current 1.5 # Y stepper motor current
beta_max_rate 36000.0 # mm/min

gamma_step_pin nc # Pin for gamma stepper step signal
gamma_dir_pin nc # Pin for gamma stepper direction
gamma_en_pin nc # Pin for gamma enable

delta_step_pin nc

System configuration

Serial communications configuration ( baud rate defaults to 9600 if undefined )

uart0.baud_rate 115200 # Baud rate for the default hardware serial port
second_usb_serial_enable false # This enables a second usb serial port (to have both pronterface
# and a terminal connected)
#leds_disable true # disable using leds after config loaded
#play_led_disable true # disable the play led

Kill button (used to be called pause) maybe assigned to a different pin, set to the onboard pin by default

kill_button_enable true # set to true to enable a kill button
kill_button_pin 2.12 # kill button pin. default is same as pause button 2.12 (2.11 is another good choice)

#msd_disable false # disable the MSD (USB SDCARD) when set to true (needs special binary)
#dfu_enable false # for linux developers, set to true to enable DFU
#watchdog_timeout 10 # watchdog timeout in seconds, default is 10, set to 0 to disable the watchdog

Only needed on a smoothieboard

currentcontrol_module_enable true #

Laser module configuration

laser_module_enable true # Whether to activate the laser module at all. All configuration is
# ignored if false.
laser_module_pwm_pin 2.2 # this pin will be PWMed to control the laser. Only P2.0 - P2.5
# can be used since laser requires hardware PWM
laser_module_ttl_pin 0.19!
laser_module_maximum_power 1.0 # this is the maximum duty cycle that will be applied to the laser
laser_module_minimum_power 0.0 # this duty cycle will be used for travel moves to keep the laser
# active without actually burning
laser_module_pwm_period 30 # this sets the pwm frequency as the period in microseconds

Endstops

endstop.xmin.enable true
endstop.xmin.pin 1.24^!
endstop.xmin.axis X
endstop.xmin.homing_direction home_to_min
endstop.xmin.homing_position -1
endstop.xmin.fast_rate 100
endstop.xmin.slow_rate 15
endstop.xmin.retract 10
endstop.xmin.limit_enable false

endstop.ymin.enable true
endstop.ymin.pin 1.26^!
endstop.ymin.axis Y
endstop.ymin.homing_direction home_to_min
endstop.ymin.homing_position -85
endstop.ymin.fast_rate 100
endstop.ymin.slow_rate 15
endstop.ymin.retract 10
endstop.ymin.limit_enable false

On boot

#on_boot_gcode /sd/on_boot.gcode # G-code file to play when the board boots.
#on_boot_gcode_enable true

Panel

#panel.enable true # set to true to enable the panel code

Example for reprap discount GLCD

on glcd EXP1 is to left and EXP2 is to right, pin 1 is bottom left, pin 2 is top left etc.

+5v is EXP1 pin 10, Gnd is EXP1 pin 9

#panel.lcd reprap_discount_glcd #
#panel.spi_channel 0 # spi channel to use ; GLCD EXP1 Pins 3,5 (MOSI, SCLK)
#panel.spi_cs_pin 0.16 # spi chip select ; GLCD EXP1 Pin 4
#panel.encoder_a_pin 3.25!^ # encoder pin ; GLCD EXP2 Pin 3
#panel.encoder_b_pin 3.26!^ # encoder pin ; GLCD EXP2 Pin 5
#panel.click_button_pin 1.30!^ # click button ; GLCD EXP1 Pin 2
#panel.buzz_pin 1.31 # pin for buzzer ; GLCD EXP1 Pin 1
##panel.back_button_pin 2.11!^ # back button ; GLCD EXP2 Pin 8
#panel.contrast 128

#panel.menu_offset 0 # some panels will need 1 here

#panel.alpha_jog_feedrate 6000 # x jogging feedrate in mm/min
#panel.beta_jog_feedrate 6000 # y jogging feedrate in mm/min
#panel.gamma_jog_feedrate 200 # z jogging feedrate in mm/min

Network settings

network.enable true # enable the ethernet network services
network.webserver.enable true # enable the webserver
network.telnet.enable true # enable the telnet server
#network.ip_address auto # use dhcp to get ip address

uncomment the 3 below to manually setup ip address

network.ip_address 192.168.99.2 # the IP address
network.ip_mask 255.255.255.0 # the ip mask
#network.ip_gateway 192.168.168.1 # the gateway address
#network.mac_override xx.xx.xx.xx.xx.xx # override the mac address, only do this if you have a conflict

Switches, bitches!

#switch.reset.enable true # Enable this module
#switch.reset.input_pin 2.11^ # Pin where reset button is connected
#switch.reset.output_on_command reset # Command to reset the board

#switch.pause.enable true # Enable this module
#switch.pause.input_pin 2.3^ # Pin where pause button is connected
#switch.pause.output_on_command suspend # Suspend command
#switch.pause.output_off_command resume # Resume command
#switch.pause.input_pin_behavior toggle # This pin toggles between it’s on and off states each time it is pressed and released

#switch.suspend.enable true # Enable this module
#switch.suspend.input_pin 0.22^ # Pin where pause button is connected
#switch.suspend.output_on_command abort # Suspend command

#switch.home.enable true
#switch.home.input_pin 0.21^
#switch.home.output_on_command M999_$H_G0X100Y100_$H

Imported from wikidot

Can you post your config, but using the normal syntax ( not the 6-axis syntax, which you shoudn’t be using ) ?

Yes, same results with that config, as soon as we set alpha_min_endstop to 1.24^! it fails in the same way.

# NOTE Lines must not exceed 132 characters
## Robot module configurations : general handling of movement G-codes and slicing into moves
arm_solution                                 cartesian        # 

default_feed_rate 10000 # Default rate ( mm/minute ) for G1/G2/G3 moves
default_seek_rate 30000 # Default rate ( mm/minute ) for G0 moves
mm_per_arc_segment 0.5 # Arcs are cut into segments ( lines ), this is the length for
# these segments. Smaller values mean more resolution,
# higher values mean faster computation
#mm_per_line_segment 5 # Lines can be cut into segments ( not usefull with cartesian
# coordinates robots ).

Arm solution configuration : Cartesian robot. Translates mm positions into stepper positions

alpha_steps_per_mm 139.058462958997222 # Steps per mm for alpha stepper
beta_steps_per_mm 69.426557463320214 # Steps per mm for beta stepper
#gamma_steps_per_mm 200 # Steps per mm for gamma stepper

Planner module configuration : Look-ahead and acceleration configuration

planner_queue_size 32 # DO NOT CHANGE THIS UNLESS YOU KNOW EXACTLY WHAT YOU ARE DOING
acceleration 700 # Acceleration in mm/second/second.
acceleration_ticks_per_second 1000 # Number of times per second the speed is updated
junction_deviation 0.05 # Similar to the old “max_jerk”, in millimeters
# Lower values mean being more careful, higher values means being
# faster and have more jerk
#minimum_planner_speed 0.0 # sets the minimum planner speed in mm/sec

Stepper module configuration

microseconds_per_step_pulse 1 # Duration of step pulses to stepper drivers, in microseconds
base_stepping_frequency 100000 # Base frequency for stepping

Cartesian axis speed limits

x_axis_max_speed 36000 # mm/min
y_axis_max_speed 36000 # mm/min
#z_axis_max_speed 30000 # mm/min

Stepper module pins ( ports, and pin numbers, appending “!” to the number will invert a pin )

alpha_step_pin 2.0o # Pin for alpha stepper step signal
alpha_dir_pin 0.5o! # Pin for alpha stepper direction
alpha_en_pin 0.4o # Pin for alpha enable pin
alpha_current 1.5 # X stepper motor current
alpha_max_rate 36000.0 # mm/min

beta_step_pin 2.1o # Pin for beta stepper step signal
beta_dir_pin 0.11o! # Pin for beta stepper direction
beta_en_pin 0.10o # Pin for beta enable
beta_current 1.5 # Y stepper motor current
beta_max_rate 36000.0 # mm/min

gamma_step_pin nc # Pin for gamma stepper step signal
gamma_dir_pin nc # Pin for gamma stepper direction
gamma_en_pin nc # Pin for gamma enable

delta_step_pin nc

System configuration

Serial communications configuration ( baud rate defaults to 9600 if undefined )

uart0.baud_rate 115200 # Baud rate for the default hardware serial port
second_usb_serial_enable false # This enables a second usb serial port (to have both pronterface
# and a terminal connected)
#leds_disable true # disable using leds after config loaded
#play_led_disable true # disable the play led

Kill button (used to be called pause) maybe assigned to a different pin, set to the onboard pin by default

kill_button_enable true # set to true to enable a kill button
kill_button_pin 2.12 # kill button pin. default is same as pause button 2.12 (2.11 is another good choice)

#msd_disable false # disable the MSD (USB SDCARD) when set to true (needs special binary)
#dfu_enable false # for linux developers, set to true to enable DFU
#watchdog_timeout 10 # watchdog timeout in seconds, default is 10, set to 0 to disable the watchdog

Only needed on a smoothieboard

currentcontrol_module_enable true #

Laser module configuration

laser_module_enable true # Whether to activate the laser module at all. All configuration is
# ignored if false.
laser_module_pwm_pin 2.2 # this pin will be PWMed to control the laser. Only P2.0 - P2.5
# can be used since laser requires hardware PWM
laser_module_ttl_pin 0.19!
laser_module_maximum_power 1.0 # this is the maximum duty cycle that will be applied to the laser
laser_module_minimum_power 0.0 # this duty cycle will be used for travel moves to keep the laser
# active without actually burning
laser_module_pwm_period 30 # this sets the pwm frequency as the period in microseconds

Endstops

endstops_enable true # the endstop module is enabled by default and can be disabled here
#corexy_homing false # set to true if homing on a hbot or corexy
alpha_min_endstop 1.24^! # add a ! to invert if endstop is NO connected to ground
alpha_max_endstop nc # NOTE set to nc if this is not installed
alpha_homing_direction home_to_min # or set to home_to_max and set alpha_max
alpha_min -1 # this gets loaded after homing when home_to_min is set
alpha_max 1600 # this gets loaded after homing when home_to_max is set
#alpha_trim 0
beta_min_endstop 1.26^! #
beta_max_endstop nc #
beta_homing_direction home_to_min #
beta_min -85 #
beta_max 3000 #
#beta_trim 0

optional order in which axis will home, default is they all home at the same time,

if this is set it will force each axis to home one at a time in the specified order

#homing_order XYZ # x axis followed by y then z last
move_to_origin_after_home false # move XY to 0,0 after homing

optional enable limit switches, actions will stop if any enabled limit switch is triggered

alpha_limit_enable false # set to true to enable X min and max limit switches
beta_limit_enable false # set to true to enable Y min and max limit switches

alpha_fast_homing_rate_mm_s 100 # feedrates in mm/second
beta_fast_homing_rate_mm_s 100 # "
alpha_slow_homing_rate_mm_s 15 # "
beta_slow_homing_rate_mm_s 15 # "

alpha_homing_retract_mm 10 # distance in mm
beta_homing_retract_mm 10 # "

On boot

#on_boot_gcode /sd/on_boot.gcode # G-code file to play when the board boots.
#on_boot_gcode_enable true

Panel

#panel.enable true # set to true to enable the panel code

Example for reprap discount GLCD

on glcd EXP1 is to left and EXP2 is to right, pin 1 is bottom left, pin 2 is top left etc.

+5v is EXP1 pin 10, Gnd is EXP1 pin 9

#panel.lcd reprap_discount_glcd #
#panel.spi_channel 0 # spi channel to use ; GLCD EXP1 Pins 3,5 (MOSI, SCLK)
#panel.spi_cs_pin 0.16 # spi chip select ; GLCD EXP1 Pin 4
#panel.encoder_a_pin 3.25!^ # encoder pin ; GLCD EXP2 Pin 3
#panel.encoder_b_pin 3.26!^ # encoder pin ; GLCD EXP2 Pin 5
#panel.click_button_pin 1.30!^ # click button ; GLCD EXP1 Pin 2
#panel.buzz_pin 1.31 # pin for buzzer ; GLCD EXP1 Pin 1
##panel.back_button_pin 2.11!^ # back button ; GLCD EXP2 Pin 8
#panel.contrast 128

#panel.menu_offset 0 # some panels will need 1 here

#panel.alpha_jog_feedrate 6000 # x jogging feedrate in mm/min
#panel.beta_jog_feedrate 6000 # y jogging feedrate in mm/min
#panel.gamma_jog_feedrate 200 # z jogging feedrate in mm/min

Network settings

network.enable true # enable the ethernet network services
network.webserver.enable true # enable the webserver
network.telnet.enable true # enable the telnet server
#network.ip_address auto # use dhcp to get ip address

uncomment the 3 below to manually setup ip address

network.ip_address 192.168.99.2 # the IP address
network.ip_mask 255.255.255.0 # the ip mask
#network.ip_gateway 192.168.168.1 # the gateway address
#network.mac_override xx.xx.xx.xx.xx.xx # override the mac address, only do this if you have a conflict

Switches, bitches!

#switch.reset.enable true # Enable this module
#switch.reset.input_pin 2.11^ # Pin where reset button is connected
#switch.reset.output_on_command reset # Command to reset the board

#switch.pause.enable true # Enable this module
#switch.pause.input_pin 2.3^ # Pin where pause button is connected
#switch.pause.output_on_command suspend # Suspend command
#switch.pause.output_off_command resume # Resume command
#switch.pause.input_pin_behavior toggle # This pin toggles between it’s on and off states each time it is pressed and released

#switch.suspend.enable true # Enable this module
#switch.suspend.input_pin 0.22^ # Pin where pause button is connected
#switch.suspend.output_on_command abort # Suspend command

#switch.home.enable true
#switch.home.input_pin 0.21^
#switch.home.output_on_command M999_$H_G0X100Y100_$H

Can you try using the very latest config file example from github, and modify nothing except enabling endstops and setting the pin ?

Then if that works, enable/configure one thing at a time and test it before moving to the next.

Ok, so heres what solved it:
I had set

gamma_step_pin nc
gamma_dir_pin nc
gamma_en_pin nc

since we have a laser cutter (only XY)

The gamma pins are used as PWM for the laser.

In previous firmwares, this worked great, but with the newer ones, we found the following to do the trick (i.e. get the board to boot):

gamma_step_pin 0.0
gamma_dir_pin 0.0
gamma_en_pin 0.0

This is not covered in any documentation that I have read…