Did you preform an ADON learn (5-25-1) after replacing the encoder ?

I'm sure u checked but they have been known to lose the rubber ring on the wheel,diameter set to 37.5mm?

Yes and yes

On your 109 fault hit select and it should give you a sub error code. What's that? And also what type of machine do you have ? MX10 or MX14 ?

109 3065 1 0
Mx10 machine
Also brake test 6-30 was set to zero yesterday. Today I saw it do one and fault, it's set to 1 now and I can only make it 1,2,3

Actually I got the encoder speeds the same using the real time display encoder estimator. Adjusting 6-64 to that, adon learn,adjust, adon learn and so on until they match at 28. High speeds are 75 and 71 though.

Is the fault happening in the same spot every time ? I believe it's your cigar switches. Either 77u top, or 77n bottom. Couple things if it's happening in the same spot of the hatch it could be your traveling cable going to those switches.
Is it flat traveling cable ?
Also could be the switch itself, as they get older those switches get sensitive you'll actually start picking up fish plate bolts with them and it will drive you crazy.
I'd do those two things travelers to the 77's or just change out the 77's . You want a good 3/8 away from the magnet to the switch.

I just don't think that those switches would cause the 197,198 faults that are actually shutting the car down. It is only happening going down, I think it may be breaking traction a little bit causing encoder faults and the 77 switches look like they come in at the wrong position. It seems to be a bit better after dialing in the rope tension better but my concern it that 4-30 shows speed of 71 both directions and 4-31 shows 76 both directions. Seems like quite a bit, and if I could get them equal I would have more room for a little error.

If you think traction is a problem, slow your accel/decel rate with parameter and see if the problem goes away. MX machines are horrible on traction. Even the underslung ones slip.

I know this may seem simplistic, I'm a simple man. So have you checked the Brakes. you may have a corner Dragging heating up the drum as it runs. Just a thought.

Ya, I went through the brakes today. Although the rope tension was pretty close, after making it perfect I could never get it to fail again and I did lower the accel and let it go. I just can't get past the encoders being 10 fpm off at only 150 fpm, and that deviation is consistent up or down. Put a new o-ring on the Gov. Encoder, no change. I have gone through all the files I have on KDM drives, initial commissioning, final, fault finding, parameters and the training manuals but no mention of adjusting this. Can't see a bad encoder just reading slow or fast, I guess if someone tells me that it's normal for these to be this far off i'll drop it.

Hey dirt, can i get those manuals?

I've seen guys take weight out of the counterweight and put them on top of the car just to see if it helps. You might be getting rollback. Can you hear the motor torque up on start ? On the ADON board when the car goes to start see if the XCT lights flicker before it goes to run. That's your encoder and it will tell you if it's moving before leaving the floor.

Do you have slides guides on the counter weights? If so check for friction mad make sure those rails are lubed.