Mesa 7I44-7I70/7I71

Looks like you have the case wrong
[ 4426.285312] hm2_5i23.0: firmware: requesting hm2/5i23/rmsvss6_8.BIT
but the file I made is rmsvss6_8.bit

I see that now but i just tried to fix it and still returns the same error. I downloaded it and it it in the directory. Latest error report
Print file information:
RUN_IN_PLACE=no
EMC2_DIR=
EMC2_BIN_DIR=/usr/bin
EMC2_TCL_DIR=/usr/lib/tcltk/emc2
EMC2_SCRIPT_DIR=
EMC2_RTLIB_DIR=/usr/realtime-2.6.32-122-rtai/modules/emc2
EMC2_CONFIG_DIR=
EMC2_LANG_DIR=/usr/share/emc/tcl/msgs
INIVAR=inivar
HALCMD=halcmd
EMC2_EMCSH=/usr/bin/wish8.5
EMC2 - 2.5.0-pre2-422-gecd2cf4
Machine configuration directory is '/home/srt/emc2/configs/10CC'
Machine configuration file is '10CC.ini'
INIFILE=/home/srt/emc2/configs/10CC/10CC.ini
PARAMETER_FILE=emc.var
EMCMOT=motmod
EMCIO=io
TASK=milltask
HALUI=halui
DISPLAY=axis
NML_FILE=
Starting EMC2...
Starting EMC2 server program: emcsvr
Loading Real Time OS, RTAPI, and HAL_LIB modules
Starting EMC2 IO program: io
Starting HAL User Interface program: halui
Shutting down and cleaning up EMC2...
Running HAL shutdown script
Killing task emcsvr, PID=4918
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments
Cleanup done

Debug file information:
insmod: error inserting '/usr/realtime-2.6.32-122-rtai/modules/emc2/hm2_pci.ko': -1 Unknown symbol in module
10CC.hal:9: exit value: 1
10CC.hal:9: insmod failed, returned -1
See the output of 'dmesg' for more information.
4918
PID TTY STAT TIME COMMAND
Stopping realtime threads
Unloading hal components

Kernel message information:
[14279.547507] I-pipe: Domain RTAI registered.
[14279.547522] RTAI[hal]: <3.8.1> mounted over IPIPE-NOTHREADS 2.6-03.
[14279.547527] RTAI[hal]: compiled with gcc version 4.4.3 (Ubuntu 4.4.3-4ubuntu5) .
[14279.547606] RTAI[hal]: mounted (IPIPE-NOTHREADS, IMMEDIATE (INTERNAL IRQs DISPATCHED), ISOL_CPUS_MASK: 0).
[14279.547611] PIPELINE layers:
[14279.547616] fd686e20 9ac15d93 RTAI 200
[14279.547621] c085cb20 0 Linux 100
[14279.593037] RTAI[malloc]: global heap size = 2097152 bytes, <BSD>.
[14279.593510] RTAI[sched]: IMMEDIATE, MP, USER/KERNEL SPACE: <with RTAI OWN KTASKs>, kstacks pool size = 524288 bytes.
[14279.593522] RTAI[sched]: hard timer type/freq = APIC/12499628(Hz); default timing: periodic; linear timed lists.
[14279.593529] RTAI[sched]: Linux timer freq = 250 (Hz), TimeBase freq = 1800080000 hz.
[14279.593535] RTAI[sched]: timer setup = 999 ns, resched latency = 2943 ns.
[14279.593658] RTAI[usi]: enabled.
[14279.678415] RTAI[math]: loaded.
[14279.805889] hm2: loading Mesa HostMot2 driver version 0.15
[14279.811317] hm2_pci: loading Mesa AnyIO HostMot2 driver version 0.7
[14279.811374] hm2_pci 0000:03:00.0: PCI INT A -> GSI 21 (level, low) -> IRQ 21
[14279.811382] hm2_pci: discovered 5i23 at 0000:03:00.0
[14279.811570] hm2_5i23.0: firmware: requesting hm2/5i23/rmsvss6_8.bit
[14279.815302] hm2/hm2_5i23.0: firmware hm2/5i23/rmsvss6_8.bit not found
[14279.815312] hm2/hm2_5i23.0: install the package containing the firmware.
[14279.815321] hm2_5i23.0: board fails HM2 registration
[14279.815353] hm2_pci 0000:03:00.0: PCI INT A disabled
[14279.815369] hm2_pci: probe of 0000:03:00.0 failed with error -2
[14280.444324] hm2: unloading
[14280.516481] RTAI[math]: unloaded.
[14280.557659] SCHED releases registered named ALIEN RTGLBH
[14280.588426] RTAI[malloc]: unloaded.
[14280.692022] RTAI[sched]: unloaded (forced hard/soft/hard transitions: traps 0, syscalls 0).
[14280.697651] I-pipe: Domain RTAI unregistered.
[14280.697741] RTAI[hal]: unmounted.

would the ini and the hal file help?

Not at this point (where the driver exits because it cannot find the selected firmware)

The firmware (rmsvss6_8.bit) needs to be installed in /lib/firmware/hm2/5i23

This will require root privleges

I copied the rmsvss6_8.bit file to the correct dir and what do you know it worked. Now I have other faults but I did make progress. Being a newby I am learning Linus as well as EMC. Thank you for the direction. Now for another question the error I get now is 'hm_25i23.0.encoder.00.counter-mode'
not found. Does this mean EMC is not seeing or finding the 7149 board? Thanks again....I Promise to research my own issues but I just don't know where to look yet and without any examples to follow I will have to rely on direction from this forum. If there is any one section of the manuals I need to study please tell me.

I means there are no encoders in the rmsvss config (only resolvers)
which means the num-encoders=N statement in your ini file needs to be changed to num_resolvers
(plus any reference to "encoders" in the HAL file need to be replaced by the resolver equivalent)
man hostmot2 should give you the names of the resolver signals

How are you making your HAL file?

I started with pncconf to get a basic layout of the ini and the hal files. I will be hand editing the rest. My configuration is just too complicated for the current version of pncconf. I also need to learn HAL because I have at least three more machines that I would like to retrofit and the more I know the better off I will be. Thanks for the links to the doc's I have printed the manuals I just can not find what I am looking for because for the most part I do not know what i am looking for yet. It took me all day yesterday just the learn how to copy my firmware file into the lib/hm2/firmware/5i23 directory. I am learning Linux at the same time.