HURCO KMB-1 Control Update

Could this lack of response to the jog wheel motion be because there are no connections to the Axis halui in the file?

Just for the record the machine is homed, but actively changing axis.x.jog-counts moves nothing.
Are the published the mpg hals I have adopted for stepper motor systems, and not appropriate for my DC servo system?

Yes, I have checked them over and over, so may have developed a blindness.

I have my rapid plus and minus buttons connected to the scale inputs.
the input pin for each one goes yellow when pressed.
axis.L.jog-scale is zero when no buttons pressed, and 1e5 for left button and 1e6 when right button is held in.
axis.L.jog-enable each of the three axes lights go yellow when the appropriate button is pressed
axis.L.jog-counts large numbers go up and down on all three axes as the wheel is turned

checked that motion.is-all-homed is TRUE , then had one last prod of the buttons, and the axis does jog on the wheel.
Only if both my plus and minus buttons are pressed together.
With both pressed the scale is .0001

What I really want to do is with those buttons is to duplicate what the rapid plus and minus do on the Axis gui

I have jogging setup as well as I can now.
Had to NOT the two switch inputs that control rate, and also enable the quadrature counting as well as adjust the mux parameters.
What I notice now is that I have to be very careful turning the wheel.
If too fast, the counts are missed, and if I get the speed of the wheel just right the axis moves in reverse.
With the original 1982 control, this wasn't an issue.
I'm going to scope the signals to ensure they are clean, but wondered if there is a max counting rate on the 7i73 that I am exceeding?
Thanks

Your hal file shows a software encoder rather than the 7I73's encoder,
A software encoder sampled at the servo thread rate will limit you to less than
1000 counts per second. You would need to use the 7I73s encoder counter to go
faster. From the 7I73 manual:

"The 7I73 can track encoder inputs up to a 50 KHz maximum count rate (4X modes).
Maximum count rate is 12.5 KHz in 1X modes and 25 KHz in 2X modes. These maximum
count rates will be reduced by quadrature distortion (deviation from 90 degree phase
difference between A and B ) so practical maximum count rates are normally somewhat
lower.

Oh dear..My poor old brain.
So, the MPG is connected to the correct pins, but the input designation I should be using is perhaps hm2_7i92.0.7i73.0.2.enc0.count to get access to the high speed values?

So take the encoder count stuff out of the hal thread and instead couple
net mpg-out ilowpass.0.in <= hm2_7i92.0.7i73.0.2.enc0.count

Yes, you don't need the hal encoder comp at all and unless you have a base thread
(not practical with an Ethernet connected device), the hal component will be quite slow.

Jogging all good now, so paying attention to getting the variable resistor potentiometers to control feedrate and spindle speed overrides.
This was complicated by the fact the Hurco has these pots internally fed with 5 volts, and I am reading the analogue voltage via 7i73 pins that tolerate 3.3volts max. However, addressed that with a resistor bridge. Then I want for the pot controls to also change the gui sliders on the Axis screen.
The attached postgui hal makes that all work, and by adjusting the scale figure can get the mid positions to align with 100%, near enough.
To get that right I have been stopping and starting the Axis gui, over and over without homing the machine and find that this "unrecognised error" message crops up sometimes, freezing the rate sliders. The Gui can stiil be shut down normally using the top right X , and generally on a restart, it works again but would like to know what the cause is.
Thanks
I have never seen this error before until I used the mult2 function in this hal.