Error ..hm2_3x20.0.pwmgen.pwm_frequency' not found

Hi!

Our machine has been off for a while, and when I try to start EMC I get an error message and is unable to start .

Does anybody have an idea what could be wrong?

Best Regards!
Lars


Print file information:
RUN_IN_PLACE=no
EMC2_DIR=
EMC2_BIN_DIR=/usr/bin
EMC2_TCL_DIR=/usr/share/emc/tcl
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 - 2.4.6
Machine configuration directory is '/home/lars/emc2/configs/Hummern'
Machine configuration file is 'Hummern.ini'
INIFILE=/home/lars/emc2/configs/Hummern/Hummern.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=2229
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments
Cleanup done

Debug file information:
hummern.hal:50: parameter or pin 'hm2_3x20.0.pwmgen.pwm_frequency' not found
2229
PID TTY STAT TIME COMMAND
Stopping realtime threads
Unloading hal components

Kernel message information:
[ 589.226534] I-pipe: Domain RTAI registered.
[ 589.226539] RTAI[hal]: <3.8.1> mounted over IPIPE-NOTHREADS 2.6-03.
[ 589.226541] RTAI[hal]: compiled with gcc version 4.4.3 (Ubuntu 4.4.3-4ubuntu5) .
[ 589.226581] RTAI[hal]: mounted (IPIPE-NOTHREADS, IMMEDIATE (INTERNAL IRQs DISPATCHED), ISOL_CPUS_MASK: 0).
[ 589.226583] PIPELINE layers:
[ 589.226585] fa1a5e20 9ac15d93 RTAI 200
[ 589.226586] c085cb20 0 Linux 100
[ 589.239641] RTAI[malloc]: global heap size = 2097152 bytes, <BSD>.
[ 589.239774] RTAI[sched]: IMMEDIATE, MP, USER/KERNEL SPACE: <with RTAI OWN KTASKs>, kstacks pool size = 524288 bytes.
[ 589.239777] RTAI[sched]: hard timer type/freq = APIC/12500448(Hz); default timing: periodic; linear timed lists.
[ 589.239779] RTAI[sched]: Linux timer freq = 250 (Hz), TimeBase freq = 3100138000 hz.
[ 589.239781] RTAI[sched]: timer setup = 999 ns, resched latency = 2943 ns.
[ 589.239836] RTAI[usi]: enabled.
[ 589.268765] RTAI[math]: loaded.
[ 589.329822] hm2: loading Mesa HostMot2 driver version 0.15
[ 589.332148] hm2_pci: loading Mesa AnyIO HostMot2 driver version 0.6
[ 589.332178] hm2_pci 0000:03:04.0: PCI INT A -> GSI 18 (level, low) -> IRQ 18
[ 589.332181] hm2_pci: discovered 3x20-1.0M at 0000:03:04.0
[ 589.332215] hm2_3x20.0: firmware: requesting hm2/3x20-1/SV24.BIT
[ 590.103475] hm2_3x20.0: Error: Not /DONE; programming not completed.
[ 590.103486] hm2/hm2_3x20.0: failed to program fpga, aborting hm2_register
[ 590.103489] hm2_3x20.0: board fails HM2 registration
[ 590.103531] hm2_pci 0000:03:04.0: PCI INT A disabled
[ 590.103542] hm2_pci: probe of 0000:03:04.0 failed with error -5
[ 590.270146] hm2_pci: driver unloaded
[ 590.272518] hm2: unloading
[ 590.302990] RTAI[math]: unloaded.
[ 590.317477] SCHED releases registered named ALIEN RTGLBH
[ 590.352193] RTAI[malloc]: unloaded.
[ 590.448032] RTAI[sched]: unloaded (forced hard/soft/hard transitions: traps 0, syscalls 0).
[ 590.450102] I-pipe: Domain RTAI unregistered.
[ 590.450140] RTAI[hal]: unmounted.

590.103475] hm2_3x20.0: Error: Not /DONE; programming not completed.

Is the actual error, this indicates a problem with the 3X20 card, power supplies, or electrical noise

If you check all power supplies, route PCIE cables away from power or motor cables and continue to get this
error, I would ask for a RMA from Mesa and return the 3X20, and host interface card for checking

Hi PCW!

After disassemblying all connectors and finally taking the 3x20 card off the 8I68 and reinstalling it, I could get Linuxcnc to start.

But there is another thing that has started about the same time as the 3x20 card refused.
When I start Linuxcnc, one of my Y servos starts to slowly move until the differens is to much between the two Y-axis servos, and then it stops with error message.
I have switched both servo motor and driver and also the 7I33 that is controlling these servos, but it behaves exactly the same way.
This happens at the first startups, and when the system has been up for a while it stops, and then after an hours milling it can suddenly stop.

Can it be that there is something wrong with the 3x20, and these two problems are related, or?

Do you have 3x20 1M + 6I68 in stock ready for fast shipment?

Best Regards!
Lars

if you get creeping on one axis I would suspect electrical noise getting into the encoder signals.
Its possible that this is a 3X20 fault but seems unlikely. I would check the wiring of that encoder/drive
wiring carefully ( Checking connections and making sure the encoder wiring is routed away from
noise sources like motor wires)

If you are running 2.6 or later you should be able to increase the encoder input
filtering by setting the encoder sample rate lower (and setting the encoder filter bit true if not already set )

A simple way to check if it's the 3x20 would be to swap this axis with another, and reprogram those two axes to be swapped. That would mean another pwm output and encoder input would be used for that axis. And then you would be able to verify if the error have moved with the 3x20 ports of if it stays in the same axis.

If it stays at the same axis with swapped ports on the Mesa card you are possibly looking at an error in the servo drive or encoder. If you have spare ports you could consider using them.

Another thing to check, does your servo drives have an offset adjustment? If it does it could be in need for an adjustment.

When the axis is creeping, are you able to measure a voltage on the output of the PWM output?

Or you should be able to program the ini file to compensate for an offset if your servo amp doesn't have adjustment for it.

Anders

Finally problem solved!

My problem with creeping on one y axis servo is now solved.

After having checked and exchanged everything connected after the 3x20/6I68 board in the following order:

-servomotor and cable to driver
-servodriver
-7I33 board
-cables between 7I33 and servodriver
-flatribbon cable between 7I33 and 6I68

still same problem.

Today I received a new set of 3x20 and 6I68 from Daniel at Cncmonster.at!

Replaced the boards and now everything is working as it should.

/Lars