Considering a Full Rewire on a Working Schaublin 125 CNC

Hi,
I worked on the configuration again today, and I think I am very close to getting it working.
The first reason I did not get the 7i83 to work yesterday was that I powered it with 5V (which was wrong). Now, with 24V and plugging it into Serial 4 (pins 1 and 14), I got it to show up in HAL Show.
I then modified the HAL file. I removed all the pwmgen stuff and changed the enable and output lines for the axes and spindle to the analog channels of the 7i83.With that, I was still able to load the configuration and enter AXIS. After flashing the correct firmware to the 7i92 (7i92t_7i85x2d.bin) and changing the serial channel in the HAL file from channel 0 to 4, it still works.

So now to my remaining problem:
Serial channels 0 to 3 in the current firmware are on the pins that were PWM outputs in the firmware I used to convince PnCconf to generate a configuration.
Now, with the “correct” firmware, these four channels seem to no longer be usable.So my question is:
where are the pin definitions stored?
I think if I can manually correct these eight pins, then I would have the configuration fully working.
I hope my explanation makes sense.
In the attached pictures, I included the pin definitions of both firmwares and an error log that shows that serial channels 0 to 3 are detected as I/O and not as serial.
 

The pin definitions are in the firmware.

In addition, the driver command line can enable/disable secondary functions.
(the primary function of all pins is GPIO)

That is, "sserial_port_0=2xxxxxxx" would only enable sserial channel 0 in mode 2
 

First of all, thank you for your help. I hope I’m not being annoying.

I tried again. If I connect the 7i83 to Smart Serial channel 0 and change the HAL file to match, the system does not work. Only channel 4 seems to work. That is the channel that worked with the firmware I used temporarily. I double-checked that the firmware which supports all five Smart Serial channels (that the 7i85 should use) is actually flashed.

I also tested the 7i73 on my mill, and it works fine, so at least that card is not faulty. However, it is not detected on any of the Smart Serial channels of the 7i85.

With the two 7i84U cards I have, I have the problem that only LEDs CR2 and CR7 are on, according to the manual. However, at least CR5 should also be on during startup. I don’t know how to troubleshoot this.

I’ve attached my HAL file as well—maybe I am doing something wrong there.
 

I tried again today.

At this point, I believe that at least some of the hardware is broken. The Smart Serial channels 0 to 3 of the 7i92t/7i85 combo do not work. I was able to get 4 of the 5 Smart Serial boards to be detected if I connect them to channel 4 of the 7i85, but on all other channels I get nothing. I don’t know if the fact that this is exactly the channel used by the bitfile I used to get a working config is a coincidence, or if I somehow managed to damage something.

I also don’t really understand how the process described in this topic works:
forum.linuxcnc.org/39-pncconf/52554-disc...ted-mesa-fpga#299687

With the described setup, there is no way to set the X and Z axes. When I try to go that route, I always get an error window in PnCconf telling me I have to set stepgen or pwmgen for the axes. So the statement “The rest of the setup in PnCconf should proceed in a more normal manner.” seems strange to me.

Regarding the 7i84U, I can get one to be detected, but I get an undervoltage error. Measuring the outputs, they do not seem to work when I set or reset them, and when I inject +24V or GND into an input, it does not change state in HAL Show either.

The second 7i84U is not detected at all, and LED CR6 does not come on.

So are both broken somehow? I don’t know.

At this point, I think my 7i73 and 7i83 are probably fine. Both 7i84Us are likely faulty, but in different ways, and either the 7i92T or the 7i85 may also have some problems.

I really don’t know how to proceed from here. Honestly, I am considering getting a 7i97T and more or less replicating the setup I use on my mill.

Do you have field power connected to both 7i84's?
I would forget PNCConf for now. If you have the 7i92 communicating with LinuxCNC, then open the HAL show, and see if you have all the pins available on the various cards.
Cheers,
Mark

One of the 7i84 cards is detected and shows all pins, with both field power (power over the RJ45) and power over the VIN pin present (not at the same time, obviously), but it gives a low-voltage error and does not seem to actually work. The second one I cannot get to be detected at all.

I really need multiple Smart Serial cards to be detected for the system to work, and on the 7i92/7i85 I can only get Smart Serial channel 4 to detect anything.