Hurco BMC 30 AP

The HAL and INI files are on page 6.
I can upload the HAL and INI files again tomorrow evening, but there are no changes in that area. Have I selected the correct channels for logging?

The commanded and fFB position are the correct ones to monitor

You might try rehoming after the first failed home so the actual motion towards home is visible
(uses a smaller scale)

I also note that HOME_FINAL_VELOCITY is 0 which as far as I can tell is not a legal value

Why does the Z-axis then work exactly as it should?
The limit switch slowly moves onto the cam. It receives the signal.
The limit switch slowly moves away from the cam and reports that the axis is referenced.

Which value do you recommend for HOME_FINAL_VELOCITY?

Its hard to tell without a halscope plot that is scaled and timed so you can actually see the motion towards home

You might disable homing to index at least temporarily at that would simplify debugging

Are you sure there are no hardware connections that disable the drives when the home switch is reached?

Edit:

For HOME_FINAL_VELOCITY you might use  a low positive number since the PID is still not tuned

Also why are the X and Y limits covering a negative range? This is standard for Z but a bit odd for X and Y

Hello everyone,
over the past few weeks we have been able to fix several bugs—mostly in the software—so that the machine is now ready for milling, even without the tool changer.
We are currently working on the tool changer and have been able to learn a great deal from the LinuxCNC documentation and successfully implement what we’ve learned.

Right now, the Yaskawa spindle inverter is giving me a bit of a headache. Perhaps there is someone here who can tell me how to connect the output signals—as shown in the pictures—within the Mesa card.
As an example: the spindle orientation function uses signal contact 39, while contact 41 serves as the common (COM). As soon as I initiate the spindle orientation and the process is complete, the VFD outputs the signal via contact 39. To verify this, I can see on the VFD's display that the signal is being generated internally; however, I am having trouble reading this signal with the Mesa card.

Another example would be speed detection. How is the signal processed?

What is the difference between Signal 34 and 35?

Since the VFDs outputs are sinking you would connect (for example):

PIN 41 --> 24V common

PIN 39 (ORE)    --> 7I97T INPUT8 (TB5 PIN 1)
PIN 35 (NDET)  --> 7I97T INPUT9 (TB5 PIN 2)

+24V --> 7I97T INCOM 8,9 (TB5 PIN 3)

Be very careful that you do not accidentally connect +24V to
any VFD output, as that will instantly destroy the VFDs optocoupler.

Thank you very much for your help. Your description provided the solution!
Unfortunately, during testing yesterday, we blew out one of the outputs. I have already ordered a new optocoupler. I also have a second inverter, but it has a fault at the encoder input, as the signal is not being detected. I installed this circuit board and on that board, the output switches correctly as well.

Perhaps someone here is familiar with the Yaskawa board. There must be a defective component somewhere on the board preventing the encoder signal from being processed. The encoder input is connector 2CN.

Unfortunately, during testing yesterday, we blew out one of the outputs.

Ouch!

A bit late, but one trick is when testing, to have a say 470 Ohm resistor in series with the +24V used for
sensing the output, that way the current is limited to ~50 mA in the event of a wrong connection.

What chip does the encoder input use? If it's differential it may be something common like a 26LS32

 

I traced the path on the circuit board a bit and came across the following two components: 75174N-H and SN75175N.

That makes sense, the 75175 is likely the differential encoder input circuit
and the 75174 is used for an emulated encoder output or some such...