After years of running, my first break down

Unfortunately that does not help because again, the hm2_pci driver did not load
You are using such an old version of LinuxCNC that it may be there are bugs in halrun/halcmd
can you try this:

halrun
halcmd: loadrt hostmot2
halcmd: loadrt hm2_pci config="firmware=hm2/5i23/SVSS6_8.BIT"
halcmd: show all

if you get an error message after the loadrt hm2_pci line, there's no reason to proceed further
if you get no errors, copy and past the whole terminal session here (you will have to scroll back to get the whole listing)
since the show command will not be useful

parameter or pin 'halcmd' not found.

If I understand correctly, I will need to update my LINUX version and LINUXCNC version to make any progress.

Thanks a lot for all your efforts, I could not have figured this out on my own.

One good thing about this is I think i will be able to get my tool changer working on the latest release as I was stalled by a bug.


One last question, do you think it is worth trying to swap out any boards?
If so, which would you choose first?

The 2 boards with a lot of wires (7I64 ?) will be very difficult to swap, the others are easy.

I think I didn't explain very well
when you run halrun in the foreground ( without the & ), it prints the halcmd: prompt
so you just type the "loadrt" etc commands not halcmd

OK, I got it now, seems obvious after it is explained.

Here is the text

Looking at the output (not knowing what I am looking for), the only thing that looks obvious is this:

5 bit RW FALSE hm2_5i23.0.io_error

I am wondering if the least effort thing to try would be replacing the 5i23?

OK so how many 7I64s do you have?

The missing pin is:

hm2_5i23.0.7i64.0.0.digin.19.in (port 0 channel 0)

But the pin list shows 2 7I64s ( port 0 channels 1 and 2 ) from the pin list:

5 bit OUT FALSE hm2_5i23.0.7i64.0.1.digin.19.in
5 bit OUT FALSE hm2_5i23.0.7i64.0.2.digin.19.in

So either you have 3 7I64s and one has quit working for some reason, of you only have 2 and you have swapped serial cables around...

PCW, thanks for looking at my problem again.

I have 2 7i64s.

I have not disconnected any wires since I built it about 5 years ago.

When you say "missing pin" does that mean that the connection to it is lost, like a wire became disconnected or whatever it is connected to is failing?

Or something internal to the control system?

Well someone must have swapped RJ45 connectors at some point, that is your pin list shows that the
2 7I64s are connected to the 7I44s channels 1 and 2, but you hal file is accessing a 7I64 at 7I44 channel 0
( and since nothing is connected to channel 0 it fails )

You probably need to look carefully at your hal file to
1. Find out what 7I64 numbers are used
2. Make sure when you fix the connections that you do not swap 7I64s as this would likely cause havoc

I am 100% sure those cables have never been disconnected, I am the only one working in the shop and the electric door has not been opened in at least a year before it stopped working.

No files on the system were edited for about a year too.

I will check all the connections to make sure nothing fell out.

Well thats pretty mysterious
Can you take a picture of the 7I44 with the cables as they are now?