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Success!
I moved that line to my posthui.hal and now everything works. 

# --- ESTOP-EXT ---
net pendant-estop     <= hm2_7i76e.0.7i76.0.0.input-29

Thx for the support. 

Its not easy to add a 3rd MPG to a 7I76E/7I76EU isolated I/O
But it would be easy to add 3 or 4 to the parallel expansion port
of a 7I76E,7I76EU,7I96,7I96S,7I95,7I95T etc as long as the MPG
just has 5V signals

Another easy way to add 4 MPG inputs to almost any card and simplify cabling
is to add a 7I73

 

I have never run this sort of mill- it originally had 3 handwheels, one for each axis, i dont know the resolution of them, but i doubt they were 100ppr, im thinking more like 200-500 to do half thou or 2 tenth motion(assuming 1 rotation was .1"), at least thats what would make sense for me.

i have another question: can a 3rd mpg encoder be added to the firmware of a 7i76e?

Also thanks a lot for the help, and this forum. amazing place!

Update / Wednesday 5:52PM: 
finally found the root cause for this behavior.
Its line 25 in my pendant.hal

# --- ESTOP-EXT ---
net pendant-estop     <=  hm2_7i76e.0.7i76.0.0.input-29

when I comment it out, everything is fine. 

Now I just have to understand whats going on with this signal.

Regards
Sebastian

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OK, I am one step closer.. I created a "virgin" configuration.. that worked fine and didnt show this error. Than I started copying my old config file by file into the new folder to narrow down when this error would be introduced.

And - believe it or not - it happens as soon as I include my pendant.hal file.

Here is a screencast. Its 100% reproducable.


As soon as "G54" is highlighted in the top left corner, everything is fine. When its "off", I always get this popup...

Does this make any sense to you?
this is my config.
github.com/SebastianMusser/LinuxCNC