Config Error When Updating and Changing from 5i25 to 7i92

I've happily been using LinuxCNC for the last 4 years using the 5i25 attached to a 7i77. I bought a 7i92M years ago as I knew I was going to go down the ethernet path eventually, and that time has come.

On a new PC I set up LinuxCNC using Rod's instructions including updating kernel to v6.4, (and I must say, the jitter result has been excellent from what I originally started with!)

I've been using PNCConf to closely match my original config file and I thought I nailed it, however, when I go to launch my config I get a num_encoders error where it thinks I only have one.

I pretty sure I have some kind of firmware error or I've selected the wrong one ("7i77x2 with on 7i77" - I assumed 'on' means 'one'?!?) - can anyone point out where I've gone wrong?

I've added the PNCConf, HAL, and INI files for starters (let me know if more are needed), and here is the error report: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 - 2.9.0~pre1+git20230208.f1270d6ed7
Machine configuration directory is '/home/cnc/linuxcnc/configs/busellato'
Machine configuration file is 'busellato.ini'
INIFILE=/home/cnc/linuxcnc/configs/busellato/busellato.ini
VERSION=1.1
PARAMETER_FILE=linuxcnc.var
TPMOD=
HOMEMOD=
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
linuxcnc TPMOD=tpmod HOMEMOD=homemod EMCMOT=motmod
Found file(REL): ./busellato.hal
Shutting down and cleaning up LinuxCNC...
Running HAL shutdown script
hm2: loading Mesa HostMot2 driver version 0.15
hm2_eth: loading Mesa AnyIO HostMot2 ethernet driver version 0.2
hm2_eth: 10.10.10.10: INFO: Hardware address (MAC): 00:60:1b:13:04:c1
hm2_eth: discovered 7I92
hm2/hm2_7i92.0: Low Level init 0.15
board fails HM2 registration
hm2_eth: in hm2_eth_reset
hm2: unloading
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments

Debug file information:
Note: Using POSIX realtime
hm2/hm2_7i92.0: config.num_encoders=4, but only 1 are available, not loading driver
hm2/hm2_7i92.0: failed to parse Module Descriptor 3
hm2_eth: rtapi_app_main: Invalid argument (-22)
./busellato.hal:9: waitpid failed /usr/bin/rtapi_app hm2_eth
./busellato.hal:9: /usr/bin/rtapi_app exited without becoming ready
./busellato.hal:9: insmod for hm2_eth failed, returned -1
2028
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:
     pastebin.com
in order to provide information about the linuxcnc
system and configuration.

                Date: Fri 04 Aug 2023 16:28:23 NZST
            UTC Date: Fri 04 Aug 2023 04:28:23 UTC
        this program: /usr/bin/linuxcnc_info
              uptime: 16:28:23 up 6 min, 1 user, load average: 1.26, 1.08, 0.55
     lsb_release -sa: Debian Debian GNU/Linux 12 (bookworm) 12 bookworm
            linuxcnc: /usr/bin/linuxcnc
                 pwd: /home/cnc/linuxcnc/configs/busellato
                USER: cnc
             LOGNAME: cnc
                HOME: /home/cnc
              EDITOR:
              VISUAL:
            LANGUAGE: en_NZ:en
                TERM: dumb
           COLORTERM:
             DISPLAY: :0.0
             DESKTOP: lightdm-xsession
        display size: 2944x1200 pixels (778x317 millimeters)
                PATH: /usr/bin:/home/cnc/linuxcnc/configs/busellato/bin:/usr/bin:/usr/local/bin:/usr/bin:/bin:/usr/local/games:/usr/games

uname items:
         nodename -n: cnc
      kernel-name -s: Linux
      kernel-vers -v: #1 SMP PREEMPT_RT Sun Jul 30 12:37:00 CEST 2023
          machine -m: x86_64
        processor -p: unknown
         platform -i: unknown
      oper system -o: GNU/Linux

/proc items:
             cmdline: BOOT_IMAGE=/boot/vmlinuz-6.4.6-rt8-linuxcnc root=UUID=11274251-5aa4-4476-b026-61f61a33aa02 ro quiet isolcpus=2,3
          model name: Intel(R) Core(TM) i5-2515E CPU @ 2.50GHz
               cores: 2
             cpu MHz: 2912.749
             parport:
              serial: 0000-0000 : serial 0000-0000 : serial 0000-0000 : serial

Versions:
                 gcc: gcc (Debian 12.2.0-14) 12.2.0
              python: Python 3.11.2
                 git: not_in_PATH
          git commit: NA
                 tcl: 8.6
                  tk: 8.6
               glade: not_in_PATH

linuxcnc_var all:

     LINUXCNCVERSION: 2.9.0~pre1+git20230208.f1270d6ed7
LINUXCNC_AUX_GLADEVCP: /usr/share/linuxcnc/aux_gladevcp
LINUXCNC_AUX_EXAMPLES: /usr/share/linuxcnc/aux_examples
            REALTIME: /usr/lib/linuxcnc/realtime
                 RTS: uspace
          HALLIB_DIR: /usr/share/linuxcnc/hallib
              PYTHON: /usr/bin/python3

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
+++-================================-===================================-============-=====================================================================
ii  linux-headers-6.4.6-rt8-linuxcnc 6.4.6-1                             amd64        Linux kernel headers for 6.4.6-rt8-linuxcnc on amd64
ii  linux-image-6.4.6-rt8-linuxcnc   6.4.6-1                             amd64        Linux kernel, version 6.4.6-rt8-linuxcnc
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                  2.9.0~pre1+git20230208.f1270d6ed7-1 all          motion controller for CNC machines and robots (English documentation)
un  linuxcnc-doc-es                  <none>                              <none>       (no description available)
un  linuxcnc-doc-fr                  <none>                              <none>       (no description available)
un  linuxcnc-sim                     <none>                              <none>       (no description available)
un  linuxcnc-sim-dev                 <none>                              <none>       (no description available)
ii  linuxcnc-uspace                  2.9.0~pre1+git20230208.f1270d6ed7-1 amd64        motion controller for CNC machines and robots
ii  linuxcnc-uspace-dev              2.9.0~pre1+git20230208.f1270d6ed7-1 amd64        PC based motion controller for real-time Linux


 

Oh, and I just remembered, when I run PNCConf it says I don't have firmware in /tmp/firmware/hm2 - not sure what to do with that?

What this command returns:
sudo mesaflash --device 7i96s -- addr 10.10.10.10 --readhmid

sudo mesaflash --device 7i96s -- addr 10.10.10.10 --readhmid

^^^  This is NOT going to work. You have to use 7i92 instead of 7i96s

Which bring the question: Did you use mesaflash to install the correct firmware for the 7i92?   (eg: 7i77x2d)

@JPL: No I did not. I figured this is probably where I went wrong. I assumed (wrongly?) the PNCConf would do that as part of the setup.
So it's the " 7i77x2d" I need to flash and not the "7i77x2 with on 7i77" as the 7i92 has the two ports P1 and P2 (although it kinda implies 2 ports)?


sudo mesaflash --device 7i92 --addr 10.10.10.10 --readhmid
Configuration Name: HOSTMOT2

General configuration information:

BoardName : MESA7I92
FPGA Size: 9 KGates
FPGA Pins: 144
Number of IO Ports: 2
Width of one I/O port: 17
Clock Low frequency: 100.0000 MHz
Clock High frequency: 200.0000 MHz
IDROM Type: 3
Instance Stride 0: 4
Instance Stride 1: 64
Register Stride 0: 256
Register Stride 1: 256

Modules in configuration:

Module: DPLL
There are 1 of DPLL in configuration
Version: 0
Registers: 7
BaseAddress: 7000
ClockFrequency: 100.000 MHz
Register Stride: 256 bytes
Instance Stride: 4 bytes

Module: WatchDog
There are 1 of WatchDog in configuration
Version: 0
Registers: 3
BaseAddress: 0C00
ClockFrequency: 100.000 MHz
Register Stride: 256 bytes
Instance Stride: 4 bytes

Module: IOPort
There are 2 of IOPort in configuration
Version: 0
Registers: 5
BaseAddress: 1000
ClockFrequency: 100.000 MHz
Register Stride: 256 bytes
Instance Stride: 4 bytes

Module: QCount
There are 1 of QCount in configuration
Version: 2
Registers: 5
BaseAddress: 3000
ClockFrequency: 100.000 MHz
Register Stride: 256 bytes
Instance Stride: 4 bytes

Module: SSerial
There are 1 of SSerial in configuration
Version: 0
Registers: 6
BaseAddress: 5A00
ClockFrequency: 100.000 MHz
Register Stride: 256 bytes
Instance Stride: 64 bytes

Module: StepGen
There are 5 of StepGen in configuration
Version: 2
Registers: 10
BaseAddress: 2000
ClockFrequency: 100.000 MHz
Register Stride: 256 bytes
Instance Stride: 4 bytes

Module: LED
There are 1 of LED in configuration
Version: 0
Registers: 1
BaseAddress: 0200
ClockFrequency: 100.000 MHz
Register Stride: 256 bytes
Instance Stride: 4 bytes

Configuration pin-out:

IO Connections for P2
DB25 pin# I/O Pri. func Sec. func Chan Sec. Pin func Sec. Pin Dir

1 0 IOPort StepGen 0 Dir/Table2 (Out)
14 1 IOPort StepGen 0 Step/Table1 (Out)
2 2 IOPort StepGen 1 Dir/Table2 (Out)
15 3 IOPort StepGen 1 Step/Table1 (Out)
3 4 IOPort StepGen 2 Dir/Table2 (Out)
16 5 IOPort StepGen 2 Step/Table1 (Out)
4 6 IOPort StepGen 3 Dir/Table2 (Out)
17 7 IOPort StepGen 3 Step/Table1 (Out)
5 8 IOPort StepGen 4 Dir/Table2 (Out)
6 9 IOPort StepGen 4 Step/Table1 (Out)
7 10 IOPort SSerial 0 TXData0 (Out)
8 11 IOPort SSerial 0 RXData0 (In)
9 12 IOPort SSerial 0 TXData1 (Out)
10 13 IOPort SSerial 0 RXData1 (In)
11 14 IOPort QCount 0 Quad-IDX (In)
12 15 IOPort QCount 0 Quad-B (In)
13 16 IOPort QCount 0 Quad-A (In)

IO Connections for P1
DB25 pin# I/O Pri. func Sec. func Chan Sec. Pin func Sec. Pin Dir

1 17 IOPort None
14 18 IOPort None
2 19 IOPort None
15 20 IOPort None
3 21 IOPort None
16 22 IOPort None
4 23 IOPort None
17 24 IOPort None
5 25 IOPort None
6 26 IOPort None
7 27 IOPort None
8 28 IOPort None
9 29 IOPort None
10 30 IOPort None
11 31 IOPort None
12 32 IOPort None
13 33 IOPort None

You need first to flash 7i92_7i77x2D.bit file from the 7i92/configs/hostmot2 directory of www.mesanet.com/software/parallel/7i92.zip according to the instruction on page 12 of the 7i92 manual. Then you will select "7i77x2 with on 7i77" with pncConf (yes on should read one)

If you aren't aware......
After you download the 7i92 zip file and have a look where the .bit files are you'll see a bunch of .pin files. These describe the pinout for the bit files.

... I'm gone for the night ...

Thanks guys, that's put me a step closer. Now erroring on my 7i77 inputs so I'll have a look at that tomorrow.