Help With a 7i96s

  Okay Guys, I need to finally ask for some help getting my 7i96s up and operational.

The backstory: My home-built CNC gantry router has used a 5i25 and 7i76 to run the I/O and the Parker CompuMotor OEM750's to drive the steppers since the day I built it nearly 10 years ago. Never had a problem in all of those years. So I've spent very little time keeping up with the nuts and bolts of Linuxcnc or the Mesa cards over that time. It just worked....until it didn't. When the 5i25/7i76 finally gave up a few weeks ago, I ordered a 7i96s to replace them. I also replaced the old Dell desktop with an HP Elitedesk 800 G2 mini (65w i5-6500).

As of yesterday, the hp mini has been loaded with the latest Linuxcnc 2.9.2 and I've created two machine configurations. One using PnCconf and the other using BigJohn's Mesa Configuration tool. I've also run mozmck's script that isolates a cpu core and sets irqbalance. Short runs of the Latency tests look pretty good. Ping times to 10.10.10.10 run consistently around .300 ms. Not that good I guess, but I haven't been able to improve them. The board, when powered, shows a solid 5V and solid 24V for field power.

Using the configuration created by the Mesa tool, the 7i96s appears to load properly, at least according to the board LEDs. The board is only populated with three proximity home switches and the connections to the x,y and z stepper drivers. Looking at the HAL pins in Axis, it appears the limit switches are operating properly. But unfortunately, the stepper motors fail to move. Any time I try a manual jog, I get an immediate following error. That happens to all 3 axes.

The configuration created by PnCconf will not run at all and throws errors when trying to start Axis.

I've attached the ini and hal files for each configuration as well as the error report from the PnCconf configuration. I just don't know enough to be be able to decipher the error log. Any and all suggestions are welcome.

Thanks,
Dean   

I tried the pncconf created config and got an error because
you have selected 2 sserial modules. You should choose
the 7i96s_d firmware when running pncconf unless you have a 7I74
(7i96s_d should be the default but is not currently)

Also the step times are likely too short (1 usec is too fast for most drives)

The MesaCT configs have a known bug, you will need to re-fetch the tool
as the version you have does not create most of the needed hal connections.

Peter, I wish I could buy you a beer. Thank you!. The firmware selection box had that as default and I didn't know any better and didn't change it. Made the correction and reloaded the configuration and everything is fine.

I still need to figure out why the Mesa tool configuration won't work properly.

Thanks again, you're a lifesaver.

I still need to figure out why the Mesa tool configuration won't work properly.

As I said I think this bug has been fixed (and very recently) 
but you would need to re-fetch mesact to have a working tool

Just did and yes it fixed it. Thanks.