5i25 configuration with only a G540, no daughterboards

Typical things that prevent step drives from running:
1. Too short step time (double to test)
2. Too high acceleration (use say 1/3 of maximum velocity as a start)
3. Wrong firmware (does the 5I25 have G540 firmware loaded?)

Found that I didn't have the microstepping box checked. That corrected the 'vibrate' problem.
Now I'm not seeing a consistent change in direction. If I use the "Test/Tune axis" button and attempt to jog with the +/- buttons, I don't always get a direction change. Does this have something to do with the direction setup/hold times? I've taken the default times for the G540. Must I adjust somewhere else?

I would use at least 5000 for all times to start

That seems to have helped a bit. It's far less likely to not change direction, however, it still drops the change every so often. Might an even larger number help that?

Might also be the step polarity
In general large values for the direction setup and hold times are
not harmful since direction is only changed at close to 0 velocity

I gave the direction signals a polarity change, without any improvement. As I use the 'tune' facility and jog an axis in each direction, there appears to be a hesitation (sounds like a bit of grumbling!) prior to an attempted change in direction by the motor. The actual direction isn't always changing ... perhaps 50% of the time.

might be a pncconf issue, I would try LinuxCNC

I understand connection between stepgen and nb. of chanel. What about inputs like E-Stop, and Limits. Are they also connected to specific channel or is it IO port nb in PnCConf?

THANK YOU for this! I've been trying to configure Machinekit on a Linux Debian Stretch box for two months without success. At least now I feel that there's hope. I'm a newbie, so please be gentle.

Symptoms: "5i25" does not appear on the mesa configure page (Page 2). My only choice is: 5i25 Internal Data.

When I attempt to add the g540x2.xml file to /lib/firmware/hm2/5i25 as root, there is no /hm2 folder.

I have downloaded and unzipped the G540 file from Mesa, and unzipped it into my Downloads folder. That gives me a path to the g540x2.xml file of: /5i25/config/hostmot2. A visual comparison of your xml file with the 5i21-g540x2.xml from there indicates that they are the same.

Any help or suggestions you might give would be GREATLY appreciated!

Thank you, again, for your time and assistance.

Leonard

I would just choose internal data and the rfx2 firmware , create a working hal/ini file set
and then edit the hal file by hand for any G540 specific I/O