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  • Gautham
  • Gautham
11 Jul 2025 06:00
5 axis milling machine with 7i96s was created by Gautham

5 axis milling machine with 7i96s

Category: Driver Boards

Hi Everyone, 

I am new here and new to CNC, Linux and Mesa boards, so pls excuse the novice questions.

This is my setup
I have a 5-axis milling machine, which uses 2 stepper motors for the z axis, so in total there are 6 stepper motors. I have also bought a servo motor ECMA-C21020RS from Delta to power my spindle. I have a Mesa 7i96s card

Now for my question
Have I bought the wrong Mesa card for my requirement? From my understanding, the 7i96s can only control 5 motors so my 6 steppers and servo exceed the capacity. If so, what would be the best solution? To buy another card and scrap the 7i96 or is there an option to buy an add-on card to work with the 7i96s?

Thank you in advance for your help
  • ZXT
  • ZXT
10 Jul 2025 20:56 - 10 Jul 2025 21:42
Configuring LinuxCNC 2.9.4 Mesa 7i95t Newbie. was created by ZXT

Configuring LinuxCNC 2.9.4 Mesa 7i95t Newbie.

Category: Milling Machines

Hello! First of all I’m sorry if this is placed in the wrong category. I’m pretty much new to Linux and LinuxCNC and been busy building a CNC mill but I’ve stumbled up on a lot of problems. 

My first thought was to get some help by using AI (Copilot) to configure Linux CNC but it doesn’t work that well because info online is limited on 2.9.4 so the AI is trying to use solutions that’s outdated for previous versions of LinuxCNC. 

The progress I’ve made so far is to configure and flash firmware to 7i95t with MesaCT and edit hall and ini files to run QTdragonHD and get the stepper motors to move but then I wanted do add 3 MPGs to jog each axis. 

Well that didn’t work that good.. these are the things I hope to accomplish one day: 

1. X-Y-Z MPGs with incremental and continuous movement. 
2. E-stop circuit (input) with reset. 
3. Add limit switches 
4.Closed loop feedback by using glass DRO scales. 
5.Spindle control 0-10v VFD or just relay control. 
6. Inputs/physical buttons: cycle start, cycle stop, 3 position resolution rotary switch for MPGs, 
7. Joystick (switches) to feed X and Y. (Like a power feed on  a manual machine) with a potentiometer to adjust feed rate) 
8. Output for fogbuster/flood coolant. 
9. Output for Compressed air nozzle. 

The list is long, 

I don’t know where to go from here.. 

Errors I’ve got earlier is missing motion.so and other modules, I’ll post the basic ini and hal files to.
 
  • BabyDibbert
  • BabyDibbert
10 Jul 2025 06:53
Fried my LinuxCNC Setup was created by BabyDibbert

Fried my LinuxCNC Setup

Category: General LinuxCNC Questions

Well, that never took off. Purchased a used PC with a parallel port breakout board and set everything up with what looked correct. Used a buck converter to power the board and noticed it wouldn’t change the voltage. Powercycled the steppers and breakout board and PC immediately turned off. Left the PC unplugged and the buck converter came to life at 26 volts, immediately blowing the caps in dramatic fashion. Well now with a fried PC and breakout board, I’d like just a ready made solution to power my lathe. I was going for Linuxcnc as I wanted spindle sync and backlash compensation, so if there are any great budget options that are just a ready made solution so I can stop worrying about wiring and flashing boards, that would be fantastic.
  • rhscdn
  • rhscdn
06 Jul 2025 16:39
Recommended card: AXYZ CNC router upgrade was created by rhscdn

Recommended card: AXYZ CNC router upgrade

Category: Driver Boards

I am looking for recommendations to upgrade the control of an AXYZ cnc router, currently configured with AMC004 + flash card and an rs-485 usb interface. I’m a longtime Linux user but 1st time CNC router owner. The cnc machine has AXYZ AXI stepper drivers and a e-trac X2C inverter driving an Elite spindle.

I’ve been reading a lot but before I go ahead and order, can anyone confirm that the 7i96s is a suitable controller card? Are there any Canadian suppliers for these cards?

Any other advice before ai get started would be greatly appreciated!
  • Russell072009
  • Russell072009
24 Jun 2025 17:21
Replied by Russell072009 on topic New with questions on LinuxCNC and Mesa

New with questions on LinuxCNC and Mesa

Category: General LinuxCNC Questions

Thanks for the info.

So the servo motors I'm looking at are integrated servo/driver/encoder and use stepper control signals. I'm under the impression that I would use a 7I95T card. Seeing as Y will have a slaved servo I'll be short one feedback channel. So I would get a 7I76 to plug in to the 7I95T correct? Then I will have all 7 feedback channels for the 4 servos and the 3 scales. It would also allow for future expansion of an A axis with feedback.

Now, If I go to run a spindle with encoder will that be handled by the 7I95T in addition to the 6 axis channels it has? Also, is this the only card I will need? It sounds like it runs ethernet to the PC and that is it.
  • Geshka
  • Geshka
19 Jun 2025 17:31
Replied by Geshka on topic How to link existing glass scale DRO readout to LinuxCNC for cheap

How to link existing glass scale DRO readout to LinuxCNC for cheap

Category: Driver Boards

I was checking your GITHUB repos - great content. I am actually working on ELS myself right now. Fitting mechanical parts first to the Atlas lathe - need to add spindle encoder and stepper tot the lead-screw.

What ELS do you use ? your own design? LinuxCNC based ?
  • Kieran
  • Kieran
19 Jun 2025 04:58 - 19 Jun 2025 05:05
Getting Ebay 2.6kw ethercat kit going. was created by Kieran

Getting Ebay 2.6kw ethercat kit going.

Category: EtherCAT

Im trying to get my 2.6kw spindle servo going. its got a P200SE drive. the instructions are written in Chinese. I used google translate and it worked pretty good. Right now im running it as a Z axis just to see if i can get it working. I got my XML setup enough that Linuxcnc reads the encoder no problem. the servo powers up and holds position along with my stepperonline X and y servos. my current roadblock is that its not listening to commands and doesnt move and it gets a following error shortly after. if i power off and turn the motor the DRO moves the distance expected so that's a good sign. the servo load meter on the PYvcp is workign for this servo too, when i "fight" the servo. i must just be missing something simple in my XML?


lcec_configgen gives me this
Warning: Spoiler!



my xml so far

Warning: Spoiler!


 
  • Sekai
  • Sekai
19 Jun 2025 03:07
Replied by Sekai on topic LinuxCNC MillTurn

LinuxCNC MillTurn

Category: General LinuxCNC Questions

Thx for the reply.
I know that linuxcnc has 9 axis in total and the name in different.
For now i have the linear guide rails and i'm working in Solidworks to build the 3d model of the entire build.
What i dont know is how to use linuxcnc for the spindle configuration.For example should i use a servomotor for the spindle head, main and subspindle or use a different style like a regular 3 phase motor with a VFD comanded by RS485 and then when i need position i can switch to servomotor or a stepper motor.
The advantage will be with 3 phase motor i can get higher rpm.
  • Sekai
  • Sekai
18 Jun 2025 19:26
LinuxCNC MillTurn was created by Sekai

LinuxCNC MillTurn

Category: General LinuxCNC Questions

Hi everybody.
I would like to build a CNC machine with 5 axis MillTurning.
Its basically like the DMG Mori CTX BETA 800 TC.
I work everyday as a cnc programmer with DMG(Siemens/Celo) and Doosan(Fanuc).
It would be a small form factor and only for light materials, like aluminiu or brass.
My ideea is :
X, Y, Z as linear axis.
C1, C2, C3 as rotary axis.
C1 is the rotary axis of the spindle head
C2 is rotary axis of main spindle (G54)
C3 is the subspindle (G55 for ex.)
BTW i know that in DMG the C1, C2, C3 are in angular mode, in turn mode is S1, S2, S3.
The Spindle head will be with a BT30. (i will machine all turn base tool holders for BT30)
The driver part i would like to use 400W to 750 W servomotors.
I would like to use Parallel port for this setup but i get the feeling i'm limiting the performance of the build.
For the moment i have some stepper motors (JSS57P2N) would like to experiment.
The build size will be maximum of 500mm between arbors (S2, S3), the Y axis max 150 mm travel, X axis 200 mm travel.
The problem i face right now is it posibil to make this cnc with linxcnc or i have to buy a different controller and software?
For now i have DELL Optiplex 745 with Intel Core2Duo CPU and 4GB Ram, AMD video card and i get about 12000ns
 latency test.
I'm trying different configurations but do not see something compatible for my purpose.
If someone build something similar from DMG style could you guide me.
Thanks
 
  • russkinch
  • russkinch's Avatar
09 Jun 2025 22:12
Encoder for rigid tapping was created by russkinch

Encoder for rigid tapping

Category: HAL

Hi,
I have a 50p/r encoder with A, B & Z. It threads perfect and can thread at 1000rpm no hassles. I am trying to do rigid tapping, but when I use G33.1, it taps to the right depth, but when the chuck reverses, the tap goes in more and not out. Its like the stepper is not being told to reverse direction. 
In my HAL file I have the three inputs setup (net spindle-phase-a encoder.0-phase-A) etc, I have the scale set to 50 and encoder mode set to 1. When I turn the chuck by hand, the position in HAL view rises by 1 for every 1 revolution of the chuck, but if I turn the chuck in the opposite direction, it carries on increasing and not count down. Is this correct? My encoder is an incremental Omron E6B2-CWZ6C. I am using a prallel port BOB (blue). Nema32 stepper motors and can control my spindle speed via the VFD (Bosch)

Any help is greatly appreciated.
  • atrex77
  • atrex77's Avatar
31 May 2025 11:52 - 31 May 2025 12:00
Replied by atrex77 on topic W5100S-EVB-PICO stepgenerator and encoder driver

W5100S-EVB-PICO stepgenerator and encoder driver

Category: Driver Boards

in the near future. The stepper-ninja hal driver run in the servo-thread so the minimum width of one input is 1 servo thread refresh in length, with 1KHz servo-thread its 1mS, something like this: when you see a ruler, all 1mm division represents a servo thread cycle, the signal only starts in the divisions and only end on the divisions. With low spindle speed its probably working, but if you want better threading you use printer port for the lathe spindle encoder.
  • npostma
  • npostma's Avatar
23 May 2025 15:13
Protecting My Mesa 7i76EU: Wiring Questions for Home Sensors and Touch Probe was created by npostma

Protecting My Mesa 7i76EU: Wiring Questions for Home Sensors and Touch Probe

Category: Basic Configuration

Hi All,I’d like your input on my planned setup.
As I mentioned in my previous post, the latency on my new machine was so high that I had to switch from the parallel port to a Mesa card. Earlier this week, I received a Mesa 7i76EU board. It looks awesome—if a bit overwhelming at first glance!My plan:
  • Motors:
    I’m using 3x Longs DM542A stepper drivers, which I plan to connect to Stepper 0/1/2 outputs on the Mesa board, using what I believe is called a “single-ended” wiring configuration. My plan is to connect +5V to the ENA+, DIR+, and STEP+ on each driver, and wire the ENA (5V), DIR-, and STEP- of each driver directly to the corresponding outputs on the Mesa card.
  • Spindle:
    I have a Huanyang VFD 1.5KW for spindle control. For now, I’ll keep my Modbus-over-USB setup, which seems to work well enough. I’ve read that getting Modbus running directly on the Mesa board requires a bit more advanced configuration, so I’ll save that for later.
  • Homing Sensors (Capacitive, 3x):
    My plan is to connect the +24V supply to the positive (brown) wire, and field ground to the negative (blue) wire of each sensor. I intend to connect the sensor output (black) wires to Input 1, 2, and 3 on the Mesa card.
Questions:
  1. Current-limiting resistor for home sensors:
    For the capacitive homing sensors, do I need to add a resistor between the output pin of the sensor and the Mesa input to protect against overcurrent? In the past, I’ve blown a few sensors and started using resistors to protect them, but those were cheap sensors—the Mesa card isn’t!
  2. 2-wire touch probe:
    For my two-wire touch-off probe, I plan to connect one side to +24V field power and the signal wire to Input 4. Here too, should I add a resistor to avoid potential shorts or overcurrent situations?
Bonus questions:
  • Any recommendations for best practices when wiring sensors and stepper drivers to the Mesa 7i76EU?
  • Are there things I should definitely avoid to protect my Mesa card or improve reliability?
  • For those who have set up Modbus on the Mesa board, how steep is the learning curve compared to using Modbus over USB?
Thanks for your advice and experiences!
  • TheRealMable
  • TheRealMable
22 May 2025 19:59 - 22 May 2025 20:01
MESA 7i76 - Lenze VFD: Where are the 10V was created by TheRealMable

MESA 7i76 - Lenze VFD: Where are the 10V

Category: Driver Boards

Hi, I my name is Chrstian and I tend to read more on forums than to write. But as many others I am in some kind of a dead end and could use some advice...

Backstory:
I bought an used self build CNC Router. The controls were build around an USB Smooth Stepper and Mach3. Since the controls are not repair friendly (too much stuff packed in too little space with custom layout boards and same color wires) and I am more a Linux than a Windows guy, I am in the process to upgrade to LinuxCNC.

I use an 7i92 and an 7i76

One of the last steps missing is the spindle control (1,5kw china spindle with ER16). For some reason the person, who built the router went with an "Lenze 822MV" 400V 2,2kw VFD.

After the long introduction, my question:
Where can I get my 10V reference (Spindle +) from this VFD? If someone might take a look and give me a hint, I would appreciate it.

The manual for the "Application IO Module" that is used, can be found here: www.becker-antriebstechnik.org/WebRoot/H...__v6-0__DE_EN_FR.pdf
(page 21 starts the english description)

The manual for the actual VFD (should not matter that much, just in case):https://www.lenze.com/en-de/products/inverters/previous-products-inverters/8200-motec

Currently connections A1, 2x7 (GND), 59, 28 and 2U are connected. I have absolutely no Idea where they go to...

In case the VFD does not have an 10V reference voltage, what are my options? Do the cheap 20€ 4channel 2,5V, 5V, 7.5V, 10V reference voltage things from ebay work?
Am I missing something?

Thanks in advance for the help (and all the help I got from the forum without having to ask).

Christian aka TheRealMable
  • npostma
  • npostma's Avatar
16 May 2025 15:05 - 16 May 2025 16:18
Replied by npostma on topic Need guidence to improve latency and speed

Need guidence to improve latency and speed

Category: Basic Configuration

I wouldn’t mind rewiring everything — my setup is quite simple, and the CNC machine is fairly small. For me, building and tweaking the CNC is part of the fun of the hobby.

I’ve read that many of you use various Mesa cards. I was hoping the 7i76EU alone would be a good starting point to learn how to work with Mesa hardware. Do you know if that’s the case? I saw some brutal shipment costs (like 200 dollar plus, so i will have to search for an European supplier, i'm in the Netherlands)

If the 7i76EU would allow me to completely move away from the parallel port, that would be a big plus — especially since I’m currently limited by base-thread latency.

[EDIT]

I see a seller with reasonable shipping costs, not sure if its a trusted compane EUSurplus?I think i am planning to switch to a Mesa board :-) and wanted to check if the 7i76EU is the right fit for my setup. This is what I’m working with:
  • 3x DM542A stepper drivers (they use step/dir signals)
  • 3x LJ12A3-4-Z/BY inductive proximity sensors (used for homing)
  • 1x Huanyang VFD (spindle, controllable via 0–10V or RS-485 Modbus (I think because i now use it over USB)
From what I’ve researched, the Mesa 7i76EU seems like the best option. Here’s why:
  • It supports up to 5 stepper/servo axes via step/dir signals (perfect for my DM542A drivers)
  • It has 32 opto-isolated inputs which should work well with the 24V NPN homing sensors
  • It has 16 outputs, which are configurable (sourcing/sinking)
  • It includes an analog spindle output (0–10V) for VFD speed control
  • It supports RS-485 communication if I decide to use Modbus for the Huanyang VFD
  • It isolates field I/O power from logic power, which helps protect the system
Important to note:
  • The sensors might need a pull-down resistor to give clean logic signals when connected to 24V. I already solderd a pc to convert the 30V signal back to a 5V system with opto's
  • I will need to supply 24V field power to the board 
  • I understand the 7i76EU requires a second Ethernet interface on my PC (either a second NIC or a USB↔Ethernet adapter)
  • I still need a PREEMPT-RT kernel, but I won't have to worry about tight base-thread latency anymore
Does this sound correct to those of you with experience using this board?Thanks in advance!

 
  • DarkPhoinix
  • DarkPhoinix
15 May 2025 14:01 - 15 May 2025 14:04
Replied by DarkPhoinix on topic Remora - ethernet NVEM / EC300 / EC500 cnc board

Remora - ethernet NVEM / EC300 / EC500 cnc board

Category: Computers and Hardware

Warning: Spoiler!

 

Thanks for reply,
I have set 12800 and testing some gcode only with Y working.
I don't want to cause problems when all the stepper and spindle are physically working.
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