My LCNC program has gone flippers

Hey Folks,

I'm at a lose here, I definitely need HELP, please!

I'm running Heron with 2.5.2, things have been going along just great for years, very few problems.

Earlier this week for some reason things got way strange:

1) The program would not load fresh CAM files. (It complained words and definitions were missing).
2) When I managed to get one file loaded, I ran it and it dropped Z to the bottom of a drilled holes and Z froze there, it went to X0Y0 and ran the entire contour stuck on the deck. What a mess! I rebooted and Z went home.
3) Now, when I load a file touch offs don't work, I put them in and nothing happens.
4) I can load and run a file that's been in the machine for sometime now, but the DRO shows all 0.000's, if I run the program and take it back home it will now show the correct position on the flash screen but the DRO still shows all zeros.

This is all on a gantry router using DC steppers.

Can anyone help get me out of this ditch?

Thank in advance for any help.

Sorry,

Unbutu Hardy Heron 8.04 is the Operating System.

The Operating System will not load fresh (or new) CAM file.

What's a simulator config?

Once again I have failed to state the problem correctly, my apologies.

LinuxCNC is not loading CAM files.
Ubuntu starts and function fine.

I would be surprised to find the HD was full, but I'll have a look straight away.

Ive been thinking I might reload 8.04, would that be a premature move?

Thanks

I have 285.2 GB of HD space available.

Nothing clever about this operator!
Nothing fancy either.

Yes, I draw and generate G-code using Synergy CAD/CAM system.

Never had a problem before.

Can you post your GCode?
Do you receive a error when loading it?

I've been told anything newer than 2.5.2 would exceed the Latency on my machine. (We tried).
I will make up a LiveCD and run it, as you say it's not permanent.

If I can get the projects being held up by this situation done I think I'll look into a newer PC so I can run the latest release.


Here's the latest G-code, this one loads just fine, I just can't position it or set the work piece height.
When I try to run it, warnings about "exceding axis travel" come up.

N1G17G20 (XY plane, Units)
N2G53G0Z0 (rapid retract quill)
N3G40G49G80 (cancel diameter, length, canned cycles)
N4G55G90G94 (set fixture, absolute, feed/minute)
N5G0X0Y0
N6M05M09
N7(MSG,LOAD T1 .2500 Twist Drill )
N8M00T1M06
N9G00X3.2099Y5.4375S1070M03
N10G04P2.5
N11G43Z1.H1
N12G83R.1Z-.1601Q.0625F4.28M08
N13X1.875Y.375
N14X9.75
N15X17.
N16X24.25
N17X32.125
N18X30.7901Y5.4375
N19G80M09
N20G00G53Z0M05
N21G49
N22G00X0Y0
N23(MSG,LOAD T1 .250 Carbide Endmill )
N24M00T1M06
N25G00X7.3934Y10.1144S3500M03
N26G04P2.5
N27G43Z1.H1
N28Z.1
N29G1Z-.085F2.M08
N30G1G41X7.3413Y10.1998D2F733.4
N31G3X7.6849Y10.1165I.2134J.1301
N32G2X7.875Y10.0098I.0651J-.1067
N33G1Y9.375
N34G3X8.125Y9.375I.125J0
N35G1Y10.3036
N36G2X8.1884Y10.4124I.125J0
N37G2X25.7078Y10.4707I8.8116J-15.5695
N38G2X25.772Y10.3615I-.0608J-.1092
N39G1Y9.375
N40G3X26.022Y9.375I.125J0
N41G1Y10.0721
N42G2X26.2114Y10.1793I.125J0
N43G2X34.1196Y.0363I-9.2114J-15.3364
N44G2X34.Y-.125I-.1196J-.0363
N45G1X0
N46G2X-.1196Y.0363I0J.125
N47G2X7.6849Y10.1165I17.1196J-5.1934
N48G3X7.7682Y10.4601I-.1302J.2134
N49G1G40X7.8202Y10.3747
N50G0Z1.M09
N51G00G49Z1.M05
N52G54Z0
N53G90X0Y0
N54M30