Linuxcnc Terminated with an Error Help

Hello,

I have recently been given a project involving trying to get linuxcnc to run a lathe in a shop. I have some linux experience, but I am completely new to LInuxCNC and CNC software in general.I am using a Mesa 5I25 with a 7177 if that matters. I have gone through the pnCConf wizard and now when I try to run the linuxcnc file generated, I get this message:

Print file information:
RUN_IN_PLACE=no
LINUXCNC_DIR=
LINUXCNC_BIN_DIR=/usr/bin
LINUXCNC_TCL_DIR=/usr/lib/tcltk/linuxcnc
LINUXCNC_SCRIPT_DIR=
LINUXCNC_RTLIB_DIR=/usr/realtime-2.6.32-122-rtai/modules/linuxcnc
LINUXCNC_CONFIG_DIR=
LINUXCNC_LANG_DIR=/usr/share/linuxcnc/tcl/msgs
INIVAR=inivar
HALCMD=halcmd
LINUXCNC_EMCSH=/usr/bin/wish8.5
LINUXCNC - 2.5.4
Machine configuration directory is '/home/paul/linuxcnc/configs/SergioTest'
Machine configuration file is 'SergioTest.ini'
INIFILE=/home/paul/linuxcnc/configs/SergioTest/SergioTest.ini
PARAMETER_FILE=linuxcnc.var
TASK=milltask
HALUI=halui
DISPLAY=axis
Starting LinuxCNC...
Starting LinuxCNC server program: linuxcncsvr
Loading Real Time OS, RTAPI, and HAL_LIB modules
Starting LinuxCNC IO program: io
Starting HAL User Interface program: halui
Shutting down and cleaning up LinuxCNC...
Running HAL shutdown script
Killing task linuxcncsvr, PID=5008
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments
Cleanup done

Debug file information:
Can not find -sec MOT -var MOT -num 1
Can not find -sec IO -var IO -num 1
Can not find -sec LINUXCNC -var NML_FILE -num 1
Can not find -sec EMC -var NML_FILE -num 1
insmod: error inserting '/usr/realtime-2.6.32-122-rtai/modules/linuxcnc/hm2_pci.ko': -1 No such device
SergioTest.hal:9: exit value: 1
SergioTest.hal:9: insmod failed, returned -1
See the output of 'dmesg' for more information.
5008
PID TTY STAT TIME COMMAND
Stopping realtime threads
Unloading hal components

Kernel message information:
[ 5433.315703] I-pipe: Domain RTAI registered.
[ 5433.315709] RTAI[hal]: <3.8.1> mounted over IPIPE-NOTHREADS 2.6-03.
[ 5433.315711] RTAI[hal]: compiled with gcc version 4.4.3 (Ubuntu 4.4.3-4ubuntu5) .
[ 5433.315762] RTAI[hal]: mounted (IPIPE-NOTHREADS, IMMEDIATE (INTERNAL IRQs DISPATCHED), ISOL_CPUS_MASK: 0).
[ 5433.315764] PIPELINE layers:
[ 5433.315766] fa5d3e20 9ac15d93 RTAI 200
[ 5433.315768] c085cb20 0 Linux 100
[ 5433.327599] RTAI[malloc]: global heap size = 2097152 bytes, <BSD>.
[ 5433.327930] RTAI[sched]: IMMEDIATE, MP, USER/KERNEL SPACE: <with RTAI OWN KTASKs>, kstacks pool size = 524288 bytes.
[ 5433.327935] RTAI[sched]: hard timer type/freq = APIC/6236400(Hz); default timing: periodic; linear timed lists.
[ 5433.327938] RTAI[sched]: Linux timer freq = 250 (Hz), TimeBase freq = 3392745000 hz.
[ 5433.327941] RTAI[sched]: timer setup = 999 ns, resched latency = 2943 ns.
[ 5433.327987] RTAI[usi]: enabled.
[ 5433.361938] RTAI[math]: loaded.
[ 5433.418409] hm2: loading Mesa HostMot2 driver version 0.15
[ 5433.420208] hm2_pci: loading Mesa AnyIO HostMot2 driver version 0.7
[ 5433.602029] hm2: unloading
[ 5433.628797] RTAI[math]: unloaded.
[ 5433.641273] SCHED releases registered named ALIEN RTGLBH
[ 5433.672209] RTAI[malloc]: unloaded.
[ 5433.772023] RTAI[sched]: unloaded (forced hard/soft/hard transitions: traps 0, syscalls 0).
[ 5433.773794] I-pipe: Domain RTAI unregistered.
[ 5433.773876] RTAI[hal]: unmounted.

Any help will be much appreciated.

The important error is this:
This means the 5I25 card was not found

Here are possible problems In approximate order of likelihood:

1. Dirty PCI slot or 5I25 contact fingers --> clean both with 99% Isopropyl alcohol

2. Low 3.3V on bus (if red LEDs on 5I25 dont go out at power up, this is likely the problem) --> replace PC power supply

3. Bad PCI slot --> try another slot or another PC if only one slot is available

4. Bad 5I25 --> if the 5I25 wont show up in any system its probably bad

Thank you for pointing me in the right direction. I have 2 identical 5I25 and I tested both on the computer and both resulted with the same error. I then tested both 5I25s with a different computer. Ran the same files and they did not result in the same error. Just to make sure, I removed the 5I25 boards and tried to run the program and the same error occurred on the new computer. I then cleaned the pci slot on the old computer but no luck. Perhaps the pci slot truly is bad on the other computer. I will be replacing the old computer with this other computer. Thanks.

Sorry for double posting, but I tried something and am confused by the results. I took the hard drive from the old computer, put it in the new computer, tried to run the linuxcnc file, and error. I then took the new hard drive, put it in the old computer, ran the linuxcnc file and it opened without error. I'm assuming this could mean something is set up wrong in the old hard drive, or that something is wrong on the new hard drive. I am not really sure.

Thank you for the response. I currently have everything on the new hard drive, so the old one is not needed. I also have another question. I finally was able to get the 5i25 with the 7i77 working and communicating (when I open the linuxcnc file, the light on the 7i77 goes from red to blinking green). When I try to move the Z-axis motor from linuxcnc, it gives me a joint axis error 2. When I move the motor manually with my hand, the rad and diameter changes numbers on my screen.

Also, if I have any questions while doing this project, should I make a whole new topic or continue posting on this thread?

Its expected that you will get joint following errors until all axis are properly wired and tuned

JT has a nice velocity mode drive tuning tutorial here:

gnipsel.com/linuxcnc/tuning/servo.html