5i20 7i33 7i37

please post both your ini and hal file as an attachment .

as requested

and again

first you cannot change 'alias' to 'setp' so don't do that.
You are using what version of EMC (apparently 2.4.x)

next what was the original error with the original pncconf produced config file?
please post the error and the hal/ini files of the original non editted version.

next what axis are you trying to test - and why have you apparently not configured steppers or PWM for the z axis?
( at least thats what it looks like from some of the HAL files. )
If the open loop test does not work that usually means you have not configured the mesa page properly.
you must have either a stepper or a PWM and encoder for each axis.
It's fairly easy to screwup and have two of one axis instead of one of each axis, and pncconf will not notice this.

I am out of town working a mill shutdown, but will answer when I can
Chris M

hi chris the first problem was the axis calibration window not coming up properly the hal and ini are the ones from version 2.4.x and the only edit is that of changing "alias pin" for setp

however the new problem is this after a fresh install of the latest linuxcnc i get throught the pncconf and can then not do the open loop testing the axis config is only two axis as the machines a plamsa gantry it has no z axis that emc controls (standalone hight control) am i better just congifing one anyway as this maybe upgraded at some point also if im going to confnig three axis am i better changing the number of encoder coounters and pwms to three or will this not affect the problem ?

the x axis im testing

try this hal file

that results in

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 - 2.5.0
Machine configuration directory is '/home/profiler/linuxcnc/configs/my_EMC_machine-1'
Machine configuration file is 'my_EMC_machine.ini'
INIFILE=/home/profiler/linuxcnc/configs/my_EMC_machine-1/my_EMC_machine.ini
PARAMETER_FILE=emc.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=1526
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
HAL: ERROR: function 'pid.0.do-pid-calcs' not found
my_EMC_machine.hal:20: addf failed
1526
PID TTY STAT TIME COMMAND
Stopping realtime threads
Unloading hal components

Kernel message information:
[ 664.179650] I-pipe: Domain RTAI registered.
[ 664.179664] RTAI[hal]: <3.8.1> mounted over IPIPE-NOTHREADS 2.6-03.
[ 664.179669] RTAI[hal]: compiled with gcc version 4.4.3 (Ubuntu 4.4.3-4ubuntu5) .
[ 664.179752] RTAI[hal]: mounted (IPIPE-NOTHREADS, IMMEDIATE (INTERNAL IRQs DISPATCHED), ISOL_CPUS_MASK: 0).
[ 664.179757] PIPELINE layers:
[ 664.179763] f8f7ce20 9ac15d93 RTAI 200
[ 664.179767] c085cb20 0 Linux 100
[ 664.225807] RTAI[malloc]: global heap size = 2097152 bytes, <BSD>.
[ 664.226141] RTAI[sched]: IMMEDIATE, MP, USER/KERNEL SPACE: <with RTAI OWN KTASKs>, kstacks pool size = 524288 bytes.
[ 664.226153] RTAI[sched]: hard timer type/freq = APIC/12500268(Hz); default timing: periodic; linear timed lists.
[ 664.226160] RTAI[sched]: Linux timer freq = 250 (Hz), TimeBase freq = 1800248000 hz.
[ 664.226166] RTAI[sched]: timer setup = 999 ns, resched latency = 2944 ns.
[ 664.226307] RTAI[usi]: enabled.
[ 664.322780] RTAI[math]: loaded.
[ 664.470196] hm2: loading Mesa HostMot2 driver version 0.15
[ 664.476008] hm2_pci: loading Mesa AnyIO HostMot2 driver version 0.7
[ 664.476059] hm2_pci: discovered 5i20 at 0000:05:00.0
[ 664.476167] hm2_5i20.0: firmware: requesting hm2/5i20/SVST8_4.BIT
[ 664.680945] hm2/hm2_5i20.0: 72 I/O Pins used:
[ 664.680955] hm2/hm2_5i20.0: IO Pin 000 (P2-01): Encoder #1, pin B (Input)
[ 664.680963] hm2/hm2_5i20.0: IO Pin 001 (P2-03): Encoder #1, pin A (Input)
[ 664.680969] hm2/hm2_5i20.0: IO Pin 002 (P2-05): Encoder #0, pin B (Input)
[ 664.680976] hm2/hm2_5i20.0: IO Pin 003 (P2-07): Encoder #0, pin A (Input)
[ 664.680983] hm2/hm2_5i20.0: IO Pin 004 (P2-09): Encoder #1, pin Index (Input)
[ 664.680990] hm2/hm2_5i20.0: IO Pin 005 (P2-11): Encoder #0, pin Index (Input)
[ 664.680997] hm2/hm2_5i20.0: IO Pin 006 (P2-13): PWMGen #1, pin Out0 (PWM or Up) (Output)
[ 664.681005] hm2/hm2_5i20.0: IO Pin 007 (P2-15): PWMGen #0, pin Out0 (PWM or Up) (Output)
[ 664.681012] hm2/hm2_5i20.0: IO Pin 008 (P2-17): PWMGen #1, pin Out1 (Dir or Down) (Output)
[ 664.681020] hm2/hm2_5i20.0: IO Pin 009 (P2-19): PWMGen #0, pin Out1 (Dir or Down) (Output)
[ 664.681027] hm2/hm2_5i20.0: IO Pin 010 (P2-21): PWMGen #1, pin Not-Enable (Output)
[ 664.681034] hm2/hm2_5i20.0: IO Pin 011 (P2-23): PWMGen #0, pin Not-Enable (Output)
[ 664.681041] hm2/hm2_5i20.0: IO Pin 012 (P2-25): Encoder #3, pin B (Input)
[ 664.681048] hm2/hm2_5i20.0: IO Pin 013 (P2-27): Encoder #3, pin A (Input)
[ 664.681055] hm2/hm2_5i20.0: IO Pin 014 (P2-29): Encoder #2, pin B (Input)
[ 664.681062] hm2/hm2_5i20.0: IO Pin 015 (P2-31): Encoder #2, pin A (Input)
[ 664.681069] hm2/hm2_5i20.0: IO Pin 016 (P2-33): Encoder #3, pin Index (Input)
[ 664.681076] hm2/hm2_5i20.0: IO Pin 017 (P2-35): Encoder #2, pin Index (Input)
[ 664.681083] hm2/hm2_5i20.0: IO Pin 018 (P2-37): PWMGen #3, pin Out0 (PWM or Up) (Output)
[ 664.681091] hm2/hm2_5i20.0: IO Pin 019 (P2-39): PWMGen #2, pin Out0 (PWM or Up) (Output)
[ 664.681098] hm2/hm2_5i20.0: IO Pin 020 (P2-41): PWMGen #3, pin Out1 (Dir or Down) (Output)
[ 664.681106] hm2/hm2_5i20.0: IO Pin 021 (P2-43): PWMGen #2, pin Out1 (Dir or Down) (Output)
[ 664.681113] hm2/hm2_5i20.0: IO Pin 022 (P2-45): PWMGen #3, pin Not-Enable (Output)
[ 664.681120] hm2/hm2_5i20.0: IO Pin 023 (P2-47): PWMGen #2, pin Not-Enable (Output)
[ 664.681127] hm2/hm2_5i20.0: IO Pin 024 (P3-01): IOPort
[ 664.681132] hm2/hm2_5i20.0: IO Pin 025 (P3-03): IOPort
[ 664.681138] hm2/hm2_5i20.0: IO Pin 026 (P3-05): IOPort
[ 664.681144] hm2/hm2_5i20.0: IO Pin 027 (P3-07): IOPort
[ 664.681149] hm2/hm2_5i20.0: IO Pin 028 (P3-09): IOPort
[ 664.681155] hm2/hm2_5i20.0: IO Pin 029 (P3-11): IOPort
[ 664.681161] hm2/hm2_5i20.0: IO Pin 030 (P3-13): IOPort
[ 664.681166] hm2/hm2_5i20.0: IO Pin 031 (P3-15): IOPort
[ 664.681172] hm2/hm2_5i20.0: IO Pin 032 (P3-17): IOPort
[ 664.681178] hm2/hm2_5i20.0: IO Pin 033 (P3-19): IOPort
[ 664.681183] hm2/hm2_5i20.0: IO Pin 034 (P3-21): IOPort
[ 664.681189] hm2/hm2_5i20.0: IO Pin 035 (P3-23): IOPort
[ 664.681195] hm2/hm2_5i20.0: IO Pin 036 (P3-25): IOPort
[ 664.681200] hm2/hm2_5i20.0: IO Pin 037 (P3-27): IOPort
[ 664.681206] hm2/hm2_5i20.0: IO Pin 038 (P3-29): IOPort
[ 664.681212] hm2/hm2_5i20.0: IO Pin 039 (P3-31): IOPort
[ 664.681217] hm2/hm2_5i20.0: IO Pin 040 (P3-33): IOPort
[ 664.681223] hm2/hm2_5i20.0: IO Pin 041 (P3-35): IOPort
[ 664.681229] hm2/hm2_5i20.0: IO Pin 042 (P3-37): IOPort
[ 664.681234] hm2/hm2_5i20.0: IO Pin 043 (P3-39): IOPort
[ 664.681240] hm2/hm2_5i20.0: IO Pin 044 (P3-41): IOPort
[ 664.681246] hm2/hm2_5i20.0: IO Pin 045 (P3-43): IOPort
[ 664.681251] hm2/hm2_5i20.0: IO Pin 046 (P3-45): IOPort
[ 664.681257] hm2/hm2_5i20.0: IO Pin 047 (P3-47): IOPort
[ 664.681263] hm2/hm2_5i20.0: IO Pin 048 (P4-01): IOPort
[ 664.681268] hm2/hm2_5i20.0: IO Pin 049 (P4-03): IOPort
[ 664.681274] hm2/hm2_5i20.0: IO Pin 050 (P4-05): IOPort
[ 664.681280] hm2/hm2_5i20.0: IO Pin 051 (P4-07): IOPort
[ 664.681285] hm2/hm2_5i20.0: IO Pin 052 (P4-09): IOPort
[ 664.681291] hm2/hm2_5i20.0: IO Pin 053 (P4-11): IOPort
[ 664.681297] hm2/hm2_5i20.0: IO Pin 054 (P4-13): IOPort
[ 664.681302] hm2/hm2_5i20.0: IO Pin 055 (P4-15): IOPort
[ 664.681308] hm2/hm2_5i20.0: IO Pin 056 (P4-17): IOPort
[ 664.681314] hm2/hm2_5i20.0: IO Pin 057 (P4-19): IOPort
[ 664.681319] hm2/hm2_5i20.0: IO Pin 058 (P4-21): IOPort
[ 664.681325] hm2/hm2_5i20.0: IO Pin 059 (P4-23): IOPort
[ 664.681331] hm2/hm2_5i20.0: IO Pin 060 (P4-25): IOPort
[ 664.681336] hm2/hm2_5i20.0: IO Pin 061 (P4-27): IOPort
[ 664.681342] hm2/hm2_5i20.0: IO Pin 062 (P4-29): IOPort
[ 664.681348] hm2/hm2_5i20.0: IO Pin 063 (P4-31): IOPort
[ 664.681353] hm2/hm2_5i20.0: IO Pin 064 (P4-33): IOPort
[ 664.681359] hm2/hm2_5i20.0: IO Pin 065 (P4-35): IOPort
[ 664.681365] hm2/hm2_5i20.0: IO Pin 066 (P4-37): IOPort
[ 664.681370] hm2/hm2_5i20.0: IO Pin 067 (P4-39): IOPort
[ 664.681376] hm2/hm2_5i20.0: IO Pin 068 (P4-41): IOPort
[ 664.681382] hm2/hm2_5i20.0: IO Pin 069 (P4-43): IOPort
[ 664.681387] hm2/hm2_5i20.0: IO Pin 070 (P4-45): IOPort
[ 664.681393] hm2/hm2_5i20.0: IO Pin 071 (P4-47): IOPort
[ 664.681613] hm2/hm2_5i20.0: registered
[ 664.681618] hm2_5i20.0: initialized AnyIO board at 0000:05:00.0
[ 665.635322] hm2_5i20.0: dropping AnyIO board at 0000:05:00.0
[ 665.635335] hm2/hm2_5i20.0: unregistered
[ 665.635409] hm2_pci: driver unloaded
[ 665.639693] hm2: unloading
[ 665.754444] RTAI[math]: unloaded.
[ 665.802351] SCHED releases registered named ALIEN RTGLBH
[ 665.832444] RTAI[malloc]: unloaded.
[ 665.932028] RTAI[sched]: unloaded (forced hard/soft/hard transitions: traps 0, syscalls 0).
[ 665.936793] I-pipe: Domain RTAI unregistered.
[ 665.936886] RTAI[hal]: unmounted.

arh ok typo on my part sorry !

change
addf pid.0.do-pid-calcs servo-thread
to
addf pid.x.do-pid-calcs servo-thread

same with chan 1 to y

also for chris just remembered that when pnc picks up my cards the sanity check wont let you get to the axis testing without posting an error of pdw generation needed

see photo

just untick the sanity check for the 7i33 should work
and over ride the checks

are you using the 7i33 ? , if so set the pdm freq to 6mhz would get you round it too perhaps