Mesa 7i92 Read Error

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03 Jun 2019 01:59 #135686 by PCW
Replied by PCW on topic Mesa 7i92 Read Error
I'd just request an RMA from Mesa and we will see if there's anything obvious thats fixable, if not we will just replace the card.

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16 Jul 2019 19:37 #139591 by 10K
Replied by 10K on topic Mesa 7i92 Read Error
Mesa took a look at the board. They tested it for 72 hours at -51C and at 100C without a problem.

I put it back in my system. It gave the read error in 1 minute. I reset and got the error in 10 minutes. Another reset and it ran for about 8 hours before the error. I pulled the Mesa board from my enclosure, and powered it by itself with an external power supply and used a different Ethernet cable. Error in 8 hours. That test confirmed to me that I'm not experiencing any sort of electrical interference from another component in the CNC electronics enclosure

I then tested it on another computer. (This was incidentally the third computer I've tried.) I installed the pre-packaged version of LinuxCNC-uspace from the LInuxCNC website. I copied over my .HAL and .INI files. I used just the board with an external power supply. It ran for 18 hours before the read error with approximately 43 million reads. (See photos. Board is shown after failure. The green ethernet light blinks when it's working, but all lights were steady when I took the photo.).

I thought about one of PCW's earlier comments about the power being interrupted. When I used alligator clips to provide power to the board, I noticed that it seemed a little touchy on the connection, and I thought that maybe the power plug was not making a good connection. I replaced the power connector with a different type. I connected the board to the regular computer it's used with, and it failed after an hour with a count of 2.5 million. (Looking back at my records, several of the failures over longer periods have been around the 3 million mark)

I'm really at wit's end with the board. I've been trying to get it working for two years, and have tried out every suggestion I've gotten. Because it sometimes takes so long to fail, it can take an entire day to test even a small change. I don't think it's the computer, since I've tried three different ones. I don't think it's the install, as I've tried both the pre-packaged install and several built up from the various parts. I don't think it's electrical interference in the enclosure. All that's left is something caused by my .HAL or .INI file, or a board defect or design problem that did not show up in Mesa's testing.

Is there something I'm missing?

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16 Jul 2019 20:25 #139592 by tecno
Replied by tecno on topic Mesa 7i92 Read Error
Run a test with UPS, you might have power-line issues.
The following user(s) said Thank You: Grotius

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16 Jul 2019 20:29 - 16 Jul 2019 20:35 #139594 by PCW
Replied by PCW on topic Mesa 7i92 Read Error
Pretty strange, maybe a little more information would give a hint:

What version ofLlinuxCNC are you running?
what does "uname -a" report?
What does "ip a" report?
What times do you get if you ping the 7I92?

Also not sure of the 7I92 firmware version, newer versions will light the /INIT LED
on a watchdog bite. This can be a handy diagnostic to determine whether you have just lost
communication (the /INIT LED will be on) or there was a power cycle/reset (The /INIT LED will be off)
Last edit: 16 Jul 2019 20:35 by PCW.

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16 Jul 2019 21:14 #139604 by 10K
Replied by 10K on topic Mesa 7i92 Read Error
I don't think it's a power outage. I live in a densely populated area. I have lots of computers. Power interruptions knock everything offline. That's not happening - especially multiple times a day. Also, assuming the possibility of micro interruptions, I installed a 220 uF capacitor on the input, which would smooth over a tiny interruption. I also tried three different power supplies, including an HP laboratory grade.

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16 Jul 2019 21:53 - 16 Jul 2019 21:58 #139612 by 10K
Replied by 10K on topic Mesa 7i92 Read Error
Currently running version 2.7.14 of LinuxCNC, but I've run several other versions over the last couple of years and had the same problem. I have never had a configuration where I didn't get the read error after a random period of time.

I've also tried multiple versions of Debian and the RT kernel. Currently, for the test machine:
Linux linuxcnc-test 4.9.0-8-rt-686-pae #1 SMP PREEMPT RT Debian 4.9.110-3+deb9u6 (2018-10-08) i686 GNU/Linux
1: lo: <LOOPBACK,UP,LOWER_UP> mtu 65536 qdisc noqueue state UNKNOWN group default qlen 1
    link/loopback 00:00:00:00:00:00 brd 00:00:00:00:00:00
    inet 127.0.0.1/8 scope host lo
       valid_lft forever preferred_lft forever
    inet6 ::1/128 scope host 
       valid_lft forever preferred_lft forever
2: eth0: <BROADCAST,MULTICAST,UP,LOWER_UP> mtu 1500 qdisc pfifo_fast state UP group default qlen 1000
    link/ether 00:19:21:30:a7:2c brd ff:ff:ff:ff:ff:ff
    inet 10.10.10.1/24 brd 10.10.10.255 scope global eth0
       valid_lft forever preferred_lft forever
    inet6 fe80::219:21ff:fe30:a72c/64 scope link 
       valid_lft forever preferred_lft forever

And the production machine:
Linux martin-lathe 4.9.0-8-rt-686-pae #1 SMP PREEMPT RT Debian 4.9.144-3.1 (2019-02-19) i686 GNU/Linux
1: lo: <LOOPBACK,UP,LOWER_UP> mtu 65536 qdisc noqueue state UNKNOWN group default qlen 1
    link/loopback 00:00:00:00:00:00 brd 00:00:00:00:00:00
    inet 127.0.0.1/8 scope host lo
       valid_lft forever preferred_lft forever
    inet6 ::1/128 scope host 
       valid_lft forever preferred_lft forever
2: eno1: <BROADCAST,MULTICAST,UP,LOWER_UP> mtu 1500 qdisc pfifo_fast state UP group default qlen 1000
    link/ether d8:cb:8a:01:c0:c8 brd ff:ff:ff:ff:ff:ff
    inet 10.10.10.1/24 brd 10.10.10.255 scope global eno1
       valid_lft forever preferred_lft forever
    inet6 fe80::dacb:8aff:fe01:c0c8/64 scope link 
       valid_lft forever preferred_lft forever

Pinging the 7i92 on the test machine gives:
PING 10.10.10.10 (10.10.10.10): 56 data bytes
64 bytes from 10.10.10.10: icmp_seq=0 ttl=64 time=5.761 ms
64 bytes from 10.10.10.10: icmp_seq=1 ttl=64 time=0.214 ms
64 bytes from 10.10.10.10: icmp_seq=2 ttl=64 time=0.220 ms
64 bytes from 10.10.10.10: icmp_seq=3 ttl=64 time=0.218 ms
64 bytes from 10.10.10.10: icmp_seq=4 ttl=64 time=0.215 ms
64 bytes from 10.10.10.10: icmp_seq=5 ttl=64 time=0.220 ms
64 bytes from 10.10.10.10: icmp_seq=6 ttl=64 time=0.214 ms
64 bytes from 10.10.10.10: icmp_seq=7 ttl=64 time=0.217 ms
64 bytes from 10.10.10.10: icmp_seq=8 ttl=64 time=0.234 ms
64 bytes from 10.10.10.10: icmp_seq=9 ttl=64 time=0.211 ms
--- 10.10.10.10 ping statistics ---
10 packets transmitted, 10 packets received, 0% packet loss
round-trip min/avg/max/stddev = 0.211/0.772/5.761/1.663 ms

And on the production machine:
PING 10.10.10.10 (10.10.10.10) 56(84) bytes of data.
64 bytes from 10.10.10.10: icmp_seq=1 ttl=64 time=0.256 ms
64 bytes from 10.10.10.10: icmp_seq=2 ttl=64 time=0.260 ms
64 bytes from 10.10.10.10: icmp_seq=3 ttl=64 time=0.251 ms
64 bytes from 10.10.10.10: icmp_seq=4 ttl=64 time=0.247 ms
64 bytes from 10.10.10.10: icmp_seq=5 ttl=64 time=0.250 ms
64 bytes from 10.10.10.10: icmp_seq=6 ttl=64 time=0.249 ms
64 bytes from 10.10.10.10: icmp_seq=7 ttl=64 time=0.251 ms
64 bytes from 10.10.10.10: icmp_seq=8 ttl=64 time=0.248 ms
64 bytes from 10.10.10.10: icmp_seq=9 ttl=64 time=0.251 ms
64 bytes from 10.10.10.10: icmp_seq=10 ttl=64 time=0.249 ms

--- 10.10.10.10 ping statistics ---
10 packets transmitted, 10 received, 0% packet loss, time 9181ms
rtt min/avg/max/mdev = 0.247/0.251/0.260/0.010 ms

I'm not sure about the 7i92 firmware version. Is there a way to figure that out? The INT light is off after the failure.
Last edit: 16 Jul 2019 21:58 by 10K. Reason: revised ip results after turned on 7i92

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16 Jul 2019 22:01 #139615 by PCW
Replied by PCW on topic Mesa 7i92 Read Error
Well the first ping of the test machine is broken (almost 6 ms)

You can check if the 7I92 has the watchdog -LED feature by exiting
LinuxCNC, if the INIT LED lights up, it has the feature

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16 Jul 2019 22:13 #139618 by tommylight
Replied by tommylight on topic Mesa 7i92 Read Error
Can you please change the IP address on the computer to 10.10.10.12 or above, gateway to 10.10.10.1 and DNS to 10.10.10.1 and test it ?

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17 Jul 2019 00:24 #139651 by 10K
Replied by 10K on topic Mesa 7i92 Read Error
I noticed the ping issue when I collected the info. I've run the ping again, and it didn't show a long initial time. I'm guessing it was caused by the way I captured the info:
ping 10.10.10.10 > ping.txt

Opening the new file probably slowed it down a bit.

When I exit LinuxCNC, the INIT light stays off, Three of the four green lights go off. I must not have the feature.

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17 Jul 2019 00:33 #139652 by PCW
Replied by PCW on topic Mesa 7i92 Read Error
You might try updating the firmware, at least it would be a bit more diagnostic

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