5i25 Meas card

Hi

I am new to Linuxcnc. I have built a PrntNC CNC Router and I have it working but I have run into a problem.
When I am jogging the machine in some spots it will continue to move slowly but the DRO's don't. When I was checking the movement with my indicator whenever I would come to a certain spot it would continue to move.
When I was using Mach3 I didn't have this problem.
I'm thinking it may be the 5i25 Mesa card because I got another BOB and it did the same thing.
I have all the wires shielded to the BOB and the drivers.
Hope someone can help with problem.
Thanks 
 

Are you saying you get uncommanded motion at certain mechanical positions?

If so this sounds like a wiring/crosstalk issue.

Yes. I can repeat the action when I move it to the same spot and it will do it on all 3 axis.Like i said when I was using Mach3 with a USB BOB I didn't have this problem and I didn't have the wires to the drivers shielded.Here are some pictures of my wiring and machine.    

Are you saying the motors move (drift) continuously in one direction at certain mechanical positions?

Can you post your hal and ini files?

Can you measure the voltage on the DIR lines to the step drives when jogging in either direction?

This does sound like an electrical noise or perhaps marginal electrical level issue

The answer to the first question is yes.
I measured the voltage on the X axis before I turn on the machine in Linuxcnc it is 5.1 volts
when I turn on the machine in Linuxcnc it drops to 2.6 volts. When I move it in a positive direction it goes back to 5.1 volts. When stopped it is 2.6 volts. When it drifts it is around 2.6 volts.
I connected a wire to the dir and the ground on the BOB to get the voltage.
What is the best way to copy hal and ini files. I am new to Linux.
Building the machine was cake compared to working with the software.
The machine runs fine except fore this problem.
Thanks
DB

The important files will be in linuxcnc/configs/ and named

xxx.hal and xxx.ini, the xxx is the name you gave the machine when
you ran pncconf

Hi
The stepper drivers I have are DM542.

[EMC]
MACHINE = CNC_Roughter
DEBUG = 0
VERSION = 1.1

[DISPLAY]
DISPLAY = axis
POSITION_OFFSET = RELATIVE
POSITION_FEEDBACK = ACTUAL
MAX_FEED_OVERRIDE = 2.000000
MAX_SPINDLE_OVERRIDE = 1.000000
MIN_SPINDLE_OVERRIDE = 0.500000
INTRO_GRAPHIC = linuxcnc.gif
INTRO_TIME = 5
PROGRAM_PREFIX = /home/bellda101/linuxcnc/nc_files
INCREMENTS = .1in .05in .01in .005in .001in .0005in .0001in
POSITION_FEEDBACK = ACTUAL
DEFAULT_LINEAR_VELOCITY = 0.250000
MAX_LINEAR_VELOCITY = 1.000000
MIN_LINEAR_VELOCITY = 0.016670
DEFAULT_ANGULAR_VELOCITY = 12.000000
MAX_ANGULAR_VELOCITY = 180.000000
MIN_ANGULAR_VELOCITY = 1.666667
EDITOR = gedit
GEOMETRY = xyz

[FILTER]
PROGRAM_EXTENSION = .png,.gif,.jpg Greyscale Depth Image
PROGRAM_EXTENSION = .py Python Script
png = image-to-gcode
gif = image-to-gcode
jpg = image-to-gcode
py = python

[TASK]
TASK = milltask
CYCLE_TIME = 0.010

[RS274NGC]
PARAMETER_FILE = linuxcnc.var
RS274NGC_STARTUP_CODE = G20 G40 G90 G94 G97 G64 P0.001

[EMCMOT]
EMCMOT = motmod
COMM_TIMEOUT = 1.0
SERVO_PERIOD = 2091797

[HMOT]
# **** This is for info only ****
CARD0=hm2_5i25.0

[HAL]
HALUI = halui
HALFILE = CNC_Roughter.hal
HALFILE = custom.hal
POSTGUI_HALFILE = postgui_call_list.hal
SHUTDOWN = shutdown.hal

[HALUI]

[KINS]
JOINTS = 3
KINEMATICS = trivkins coordinates=XYZ

[TRAJ]
COORDINATES = XYZ
LINEAR_UNITS = inch
ANGULAR_UNITS = degree
DEFAULT_LINEAR_VELOCITY = 0.17
MAX_LINEAR_VELOCITY = 1.67
NO_FORCE_HOMING = 1

[EMCIO]
EMCIO = io
CYCLE_TIME = 0.100
TOOL_TABLE = tool.tbl

#******************************************
[AXIS_X]
MAX_VELOCITY = 1.66666666667
MAX_ACCELERATION = 30.0
MIN_LIMIT = -0.001
MAX_LIMIT = 32.0

[JOINT_0]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.5
MIN_FERROR = 0.05
MAX_VELOCITY = 1.66666666667
MAX_ACCELERATION = 30.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 2.08
STEPGEN_MAXACCEL = 37.50
P = 979.007149689
I = 0.0
D = 0.0
FF0 = 0.0
FF1 = 1.0
FF2 = 0.0
BIAS = 0.0
DEADBAND = 0.0
MAX_OUTPUT = 0.0
# these are in nanoseconds
DIRSETUP = 5000
DIRHOLD = 10000
STEPLEN = 2500
STEPSPACE = 2500
STEP_SCALE = 4064.0
MIN_LIMIT = -0.001
MAX_LIMIT = 32.0
HOME_OFFSET = 0.000000
HOME_SEARCH_VEL = -0.816667
HOME_LATCH_VEL = 0.016667
HOME_FINAL_VEL = 0.000000
HOME_USE_INDEX = NO
HOME_IGNORE_LIMITS = YES
HOME_IS_SHARED = 1
HOME_SEQUENCE = 1
#******************************************

#******************************************
[AXIS_Y]
MAX_VELOCITY = 1.66666666667
MAX_ACCELERATION = 30.0
MIN_LIMIT = -0.001
MAX_LIMIT = 21.0

[JOINT_1]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.5
MIN_FERROR = 0.05
MAX_VELOCITY = 1.66666666667
MAX_ACCELERATION = 30.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 2.08
STEPGEN_MAXACCEL = 37.50
P = 979.007149689
I = 0.0
D = 0.0
FF0 = 0.0
FF1 = 1.0
FF2 = 0.0
BIAS = 0.0
DEADBAND = 0.0
MAX_OUTPUT = 0.0
# these are in nanoseconds
DIRSETUP = 5000
DIRHOLD = 10000
STEPLEN = 2500
STEPSPACE = 2500
STEP_SCALE = 4064.0
MIN_LIMIT = -0.001
MAX_LIMIT = 21.0
HOME_OFFSET = 0.000000
HOME_SEARCH_VEL = -0.816667
HOME_LATCH_VEL = 0.016667
HOME_FINAL_VEL = 0.000000
HOME_USE_INDEX = NO
HOME_IGNORE_LIMITS = YES
HOME_IS_SHARED = 1
HOME_SEQUENCE = 2
#******************************************

#******************************************
[AXIS_Z]
MAX_VELOCITY = 1.0
MAX_ACCELERATION = 30.0
MIN_LIMIT = -4.0
MAX_LIMIT = 0.001

[JOINT_2]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.5
MIN_FERROR = 0.05
MAX_VELOCITY = 1.0
MAX_ACCELERATION = 30.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 1.25
STEPGEN_MAXACCEL = 37.50
P = 979.007149689
I = 0.0
D = 0.0
FF0 = 0.0
FF1 = 1.0
FF2 = 0.0
BIAS = 0.0
DEADBAND = 0.0
MAX_OUTPUT = 0.0
# these are in nanoseconds
DIRSETUP = 5000
DIRHOLD = 10000
STEPLEN = 2500
STEPSPACE = 2500
STEP_SCALE = 10160.0
MIN_LIMIT = -4.0
MAX_LIMIT = 0.001
HOME_OFFSET = 0.000000
HOME_SEARCH_VEL = -0.050000
HOME_LATCH_VEL = -0.016667
HOME_FINAL_VEL = 0.000000
HOME_USE_INDEX = NO
HOME_IGNORE_LIMITS = YES
HOME_IS_SHARED = 1
HOME_SEQUENCE = 0
#******************************************

[SPINDLE_0]
P = 0
I = 0
D = 0
FF0 = 1
FF1 = 0
FF2 = 0
BIAS = 0
DEADBAND = 0
MAX_OUTPUT = 2000
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