Mill has been running fine for years, all of a sudden I get the following error

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31 Oct 2024 20:25 #313552 by B.Reilly01
My mill has been running a very basic AXIS HAL and INI files and doing fine for years.  It is not connected to the internet, so it didn't do an unexpected update.  All of a sudden I get the following on start up:
Error report created by /usr/lib/tcltk/linuxcnc/show_errors.tcl:

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/lib/linuxcnc/modules
LINUXCNC_CONFIG_DIR=
LINUXCNC_LANG_DIR=/usr/lib/tcltk/linuxcnc/msgs
INIVAR=inivar
HALCMD=halcmd
LINUXCNC_EMCSH=/usr/bin/wish8.6
LINUXCNC - 2.8.0~pre1
Machine configuration directory is '/home/cncmill/linuxcnc/configs/3500rpm_Hurco_SM1'
Machine configuration file is '3500rpm_Hurco_SM1.ini'
INIFILE=/home/cncmill/linuxcnc/configs/3500rpm_Hurco_SM1/3500rpm_Hurco_SM1.ini
VERSION=1.1
PARAMETER_FILE=linuxcnc.var
TASK=milltask
HALUI=halui
DISPLAY=axis
COORDINATES=XYZ
KINEMATICS=trivkins coordinates=XYZ
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
Found file(REL): ./3500rpm_Hurco_SM1.hal
Shutting down and cleaning up LinuxCNC...
Running HAL shutdown script
hm2: loading Mesa HostMot2 driver version 0.15
hm2_pci: loading Mesa AnyIO HostMot2 driver version 0.7
hm2: unloading
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments

Debug file information:
Note: Using POSIX realtime
hm2_pci: rtapi_app_main: No such device (-19)
./3500rpm_Hurco_SM1.hal:9: waitpid failed /usr/bin/rtapi_app hm2_pci
./3500rpm_Hurco_SM1.hal:9: /usr/bin/rtapi_app exited without becoming ready
./3500rpm_Hurco_SM1.hal:9: insmod for hm2_pci failed, returned -1
2986
Stopping realtime threads
Unloading hal components
Note: Using POSIX realtime



-----------------------------------------------------------------------
Info report created by linuxcnc_info:
The file:    /tmp/linuxcnc_info.txt
can be posted to a forum or a web site like:
     http://pastebin.com
in order to provide information about the linuxcnc
system and configuration.

                Date: Thu Oct 31 10:59:53 CDT 2024
            UTC Date: Thu Oct 31 15:59:53 UTC 2024
        this program: /usr/bin/linuxcnc_info
              uptime: 10:59:53 up 4 min, 1 user, load average: 0.38, 1.12, 0.60
     lsb_release -sa: LinuxMint Linuxcnc Uspace Powered by Linux Mint 19.2 Tina 19.2 tina
      which linuxcnc: /usr/bin/linuxcnc
                 pwd: /home/cncmill/linuxcnc/configs/3500rpm_Hurco_SM1
                USER: cncmill
             LOGNAME: cncmill
                HOME: /home/cncmill
              EDITOR: 
              VISUAL: 
            LANGUAGE: en_US
                TERM: dumb
           COLORTERM: 
             DISPLAY: :0
             DESKTOP: mate
        display size: 1024x768 pixels (270x203 millimeters)
                PATH: /usr/bin:/home/cncmill/linuxcnc/configs/3500rpm_Hurco_SM1/bin:/usr/bin:/usr/local/sbin:/usr/local/bin:/usr/sbin:/usr/bin:/sbin:/bin:/usr/games:/usr/local/games:/snap/bin

uname items:
         nodename -n: CNC-Mill
      kernel-name -s: Linux
      kernel-vers -v: #1 SMP PREEMPT RT Thu Mar 5 00:02:34 AEDT 2020
          machine -m: x86_64
        processor -p: x86_64
         platform -i: x86_64
      oper system -o: GNU/Linux

/proc items:
             cmdline: BOOT_IMAGE=/boot/vmlinuz-4.19.106-rt44-lcnc root=UUID=69380275-e756-469f-a27d-d74d6649283d ro quiet splash vt.handoff=1
          model name: Intel(R) Atom(TM) CPU D2550 @ 1.86GHz
               cores: 2
             cpu MHz: 1861.981
             parport: 0000-0000 : parport0
              serial: 0000-0000 : serial 0000-0000 : serial

Versions:
                 gcc: gcc (Ubuntu 7.5.0-3ubuntu1~18.04) 7.5.0
              python: Python 2.7.17
                 git: git version 2.17.1
          git commit: NA
                 tcl: 8.6
                  tk: 8.6
               glade: not_in_PATH
          glade-gtk2: not_in_PATH

linuxcnc_var all:

     LINUXCNCVERSION: 2.8.0~pre1
LINUXCNC_AUX_GLADEVCP: /usr/share/linuxcnc/aux_gladevcp
LINUXCNC_AUX_EXAMPLES: /usr/share/linuxcnc/aux_examples
            REALTIME: /etc/init.d/realtime
                 RTS: uspace
          HALLIB_DIR: /usr/share/linuxcnc/hallib

dpkg -l '*linuxcnc*':
Desired=Unknown/Install/Remove/Purge/Hold
| Status=Not/Inst/Conf-files/Unpacked/halF-conf/Half-inst/trig-aWait/Trig-pend
|/ Err?=(none)/Reinst-required (Status,Err: uppercase=bad)
||/ Name                Version                      Architecture Description
+++-===================-============================-============-=====================================================================
un  linuxcnc            <none>                       <none>       (no description available)
un  linuxcnc-dev        <none>                       <none>       (no description available)
un  linuxcnc-doc        <none>                       <none>       (no description available)
ii  linuxcnc-doc-en     1:2.8.0~pre1.5821.g7525a1528 all          motion controller for CNC machines and robots (English documentation)
un  linuxcnc-sim        <none>                       <none>       (no description available)
un  linuxcnc-sim-dev    <none>                       <none>       (no description available)
ii  linuxcnc-uspace     1:2.8.0~pre1.5821.g7525a1528 amd64        motion controller for CNC machines and robots
ii  linuxcnc-uspace-dev 1:2.8.0~pre1.5821.g7525a1528 amd64        PC based motion controller for real-time Linux

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31 Oct 2024 21:15 - 31 Oct 2024 21:17 #313555 by PCW
hm2_pci: rtapi_app_main: No such device (-19)


Looks like the PCI card is not found, common issues
are dirty slots, (clean card edge connector and slot with 99% isopropanol),
on 5I25/6I25: low 3.3V from PC power supply (replace PC power supply),
failed PC, failed PCI card.
Last edit: 31 Oct 2024 21:17 by PCW.
The following user(s) said Thank You: B.Reilly01

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01 Nov 2024 00:41 #313560 by B.Reilly01
Thanks for the quick response, looks like it's the 5i25 card. There were no LEDs on on the card, so I unplugged it and reseated it. The init and /Done leds flickered and went out. So I took it to another PC, same behavior,

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01 Nov 2024 03:08 #313568 by tommylight
Use alcohol to clean the pins on the 5i25 card and inside the PC slot, use an old cotton t-shirt for the first and an old tooth brush for the second, leave to dry for an hour or use compressed air to dry faster, then plug in.
Also use a voltmeter and measure on the main 20 or 24 pin mainboard connector between any of the black wires and an orange wire, it should be 3.3V, anything lower than 3.1 will probably not work, PCW knows this best.

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01 Nov 2024 22:25 #313636 by B.Reilly01
After reading the manual again, it looks like there shouldn't be any LEDs on. I cleaned everything up and plugged it back in and now Mesaflash can see it again.

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