Error starting LINUXCNC

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05 Feb 2013 04:26 #29600 by Will Gilmore
I went to start up LINUXCNC this morning. It started to open and then closed and gave me the following error message. I changed the monitor a few days ago but I think it was working since then, maybe not I cant remember. Any ideas?

Print file information:
RUN_IN_PLACE=no
EMC2_DIR=
EMC2_BIN_DIR=/usr/bin
EMC2_TCL_DIR=/usr/lib/tcltk/emc2
EMC2_SCRIPT_DIR=
EMC2_RTLIB_DIR=/usr/realtime-2.6.32-122-rtai/modules/emc2
EMC2_CONFIG_DIR=
EMC2_LANG_DIR=/usr/share/emc/tcl/msgs
INIVAR=inivar
HALCMD=halcmd
EMC2_EMCSH=/usr/bin/wish8.5
EMC2 - 2.5.0-pre2-626-g402b6cd
Machine configuration directory is '/home/gotham/emc2/configs/Tree_Journeyman_320'
Machine configuration file is 'Tree_Journeyman_320.ini'
INIFILE=/home/gotham/emc2/configs/Tree_Journeyman_320/Tree_Journeyman_320.ini
PARAMETER_FILE=emc.var
EMCMOT=motmod
EMCIO=io
TASK=milltask
HALUI=halui
DISPLAY=axis
NML_FILE=
Starting EMC2...
Starting EMC2 server program: emcsvr
Loading Real Time OS, RTAPI, and HAL_LIB modules
Starting EMC2 IO program: io
Starting HAL User Interface program: halui
Shutting down and cleaning up EMC2...
Running HAL shutdown script
Killing task emcsvr, PID=2033
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments
Cleanup done

Debug file information:
insmod: error inserting '/usr/realtime-2.6.32-122-rtai/modules/emc2/hm2_pci.ko': -1 Input/output error
Tree_Journeyman_320.hal:9: exit value: 1
Tree_Journeyman_320.hal:9: insmod failed, returned -1
See the output of 'dmesg' for more information.
2033
PID TTY STAT TIME COMMAND
Stopping realtime threads
Unloading hal components

Kernel message information:
[ 2411.840880] I-pipe: Domain RTAI registered.
[ 2411.840885] RTAI[hal]: <3.8.1> mounted over IPIPE-NOTHREADS 2.6-03.
[ 2411.840886] RTAI[hal]: compiled with gcc version 4.4.3 (Ubuntu 4.4.3-4ubuntu5) .
[ 2411.840907] RTAI[hal]: mounted (IPIPE-NOTHREADS, IMMEDIATE (INTERNAL IRQs DISPATCHED), ISOL_CPUS_MASK: 0).
[ 2411.840908] PIPELINE layers:
[ 2411.840910] fab4be20 9ac15d93 RTAI 200
[ 2411.840912] c085cb20 0 Linux 100
[ 2411.853624] RTAI[malloc]: global heap size = 2097152 bytes, <BSD>.
[ 2411.853694] RTAI[sched]: IMMEDIATE, MP, USER/KERNEL SPACE: <with RTAI OWN KTASKs>, kstacks pool size = 524288 bytes.
[ 2411.853698] RTAI[sched]: hard timer type/freq = APIC/20780891(Hz); default timing: periodic; linear timed lists.
[ 2411.853700] RTAI[sched]: Linux timer freq = 250 (Hz), TimeBase freq = 2992592000 hz.
[ 2411.853702] RTAI[sched]: timer setup = 999 ns, resched latency = 2943 ns.
[ 2411.853749] RTAI[usi]: enabled.
[ 2411.878267] RTAI[math]: loaded.
[ 2411.931061] hm2: loading Mesa HostMot2 driver version 0.15
[ 2411.932623] hm2_pci: loading Mesa AnyIO HostMot2 driver version 0.7
[ 2411.932645] hm2_pci: discovered 5i20 at 0000:07:04.0
[ 2411.932708] hm2_5i20.0: firmware: requesting hm2/5i20/SV12_2X7I48_72.BIT
[ 2411.934041] hm2_5i20.0: FPGA did not reset: /INIT = 1, DONE = 1
[ 2411.934044] hm2/hm2_5i20.0: failed to reset fpga, aborting hm2_register
[ 2411.934047] hm2_5i20.0: board fails HM2 registration
[ 2411.934052] hm2_pci: probe of 0000:07:04.0 failed with error -5
[ 2412.105933] hm2: unloading
[ 2412.125297] RTAI[math]: unloaded.
[ 2412.143965] SCHED releases registered named ALIEN RTGLBH
[ 2412.172208] RTAI[malloc]: unloaded.
[ 2412.272009] RTAI[sched]: unloaded (forced hard/soft/hard transitions: traps 0, syscalls 0).
[ 2412.273544] I-pipe: Domain RTAI unregistered.
[ 2412.273567] RTAI[hal]: unmounted.

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05 Feb 2013 04:42 #29602 by BigJohnT
Replied by BigJohnT on topic Error starting LINUXCNC
See what Tree_Journeyman_320.hal line 9 says... it errored out there.

John

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05 Feb 2013 04:54 #29604 by Will Gilmore
Here is the beginning of the hal file. I'm not sure if it counts comments and blank lines.

# Generated by PNCconf at Fri Mar 30 15:19:35 2012
# If you make changes to this file, they will be
# overwritten when you run PNCconf again

loadrt trivkins
loadrt [EMCMOT]EMCMOT servo_period_nsec=[EMCMOT]SERVO_PERIOD num_joints=[TRAJ]AXES
loadrt probe_parport
loadrt hostmot2
loadrt hm2_pci config="firmware=hm2/5i20/SV12_2X7I48_72.BIT num_encoders=3 num_pwmgens=3 num_3pwmgens=0 num_stepgens=0 "
setp hm2_5i20.0.pwmgen.pwm_frequency 24000
setp hm2_5i20.0.pwmgen.pdm_frequency 6000
setp hm2_5i20.0.watchdog.timeout_ns 10000000
loadrt pid names=pid.x,pid.y,pid.z

addf hm2_5i20.0.read servo-thread
addf motion-command-handler servo-thread
addf motion-controller servo-thread
addf pid.x.do-pid-calcs servo-thread
addf pid.y.do-pid-calcs servo-thread
addf pid.z.do-pid-calcs servo-thread
addf hm2_5i20.0.write servo-thread
addf hm2_5i20.0.pet_watchdog servo-thread

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05 Feb 2013 04:56 - 05 Feb 2013 05:00 #29605 by Will Gilmore
I took out the comments and the blank line below them. It now errors out on line 5 which is

loadrt hm2_pci config="firmware=hm2/5i20/SV12_2X7I48_72.BIT num_encoders=3 num_pwmgens=3 num_3pwmgens=0 num_stepgens=0 "
Last edit: 05 Feb 2013 05:00 by Will Gilmore.

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05 Feb 2013 05:54 #29608 by PCW
Replied by PCW on topic Error starting LINUXCNC
This looks like a bad FPGA card /MB problem to me:

[ 2411.934041] hm2_5i20.0: FPGA did not reset: /INIT = 1, DONE = 1
[ 2411.934044] hm2/hm2_5i20.0: failed to reset fpga, aborting hm2_register

You might try disconnecting the cables and re-seating the card and see if you
get the same error with nothing connected, If you do it may be:

1. Bad FPGA/bridge chip or bad EEPROM on FPGA card
2. Bad / dirty motherboard PCI slot
The following user(s) said Thank You: Will Gilmore

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07 Feb 2013 02:27 #29719 by Will Gilmore
After reseating the FPGA card in the PCI slot which didn't solve the problem I reseated the 50 pin connectors on the FPGA PCI card. Presto! Thanks!

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07 Feb 2013 02:34 #29720 by PCW
Replied by PCW on topic Error starting LINUXCNC
Hmm... My guess is that theres' a bad solder joint on the card that has been made to work by mechanical shifting
can you send an email to tech@mesanet requesting an RMA #?

With a formal RMA request, we can send a replacement card and you can return the (I think questionable) card when the new one arrives.

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