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I replaced the optocoupler, and the output is working again.I attempted to set up the tool changer. Unfortunately, I keep receiving the following error messages when starting LinuxCNC. Attached is my .ini file.

I don't think that a better debounce is the solution. We really ought to be able to solve this in the base code. Unless you have a probe that ounces after the machine has stopped moving.

You may have set the deceleration and acceleration ramps too steeply 

The controller doesn't care about the size of the motors, and there are many working EtherCAT systems out there running LinuxCNC.

You probably want to be running the master / dev version of LinuxCNC at the moment as there are various new features aimed at EtherCAT in there (for example the ability to run a initialisation step in the drivers as soon as realtime starts).

First see if you can work out or find documented the Denavit-Hartenberg parameters for the robot.
Also look at the sample robot configs which include a visualisation of the robot, For example:
linuxcnc/configs/sim/axis/vismach/puma/ in the config picker.

Have you tried creating a config with either the built-in PnCConf wizard, or the MesaCT wizard?

linuxcnc.org/docs/stable/html/config/pncconf.html

github.com/jethornton/mesact

I can't help with a fix, but it might help to work out where the fix belongs.
Try plotting the position-cmd in Halscope to see if the problem is in the commands from the WHB or is inside HAL itself.

If you can measure the pitch then you might be able to find it here:
connectorbook.com/identification.html?N=..._full_size_rect_conn

But it looks like standard 0.1" pitch so many things might fit. I would try the "dupont" style.
connectorbook.com/identification.html?N=&n=shroudless_plugs

On the top Right menu of the boot screen I have options for: 
Default Xsession
Gnome classic on Xorg
Gnome Classic
Gnome on wayland
Xfce Session
Only the Default Xsession and the Xfce session works. The others give me a white screen that says "Oh no. Something has gone wrong and the system cannot recover. Please log out and try again". There is also a sweet little icon of a computer screen and a sad face. Much of the googling I have done suggests that onboard only works with a few window managers.
Thanks gain

Got the inputs figured out.

1.  Program drive so all inputs are 'no function assigned'

2. Change xml input address HAL name:
3. Add bitslice to HAL, using the bit chart from the servo manual:
Now I can press buttons connected to the drive and all five inputs react in halshow.  Rather exciting...

Next step is to see if I can fumble through changing the PDOs to 'fixed' and somehow map the outputs.

Anyone have a clue what 'sub-index 1' means?
 

Hi All hope everyone is good.
So I am considering going the LinuxCNC with EtherCat  route as opposed to a Inovance EtherCat Controller route.
So the Motors are as Follower
3 x 4.4KW Servo Motors from JSS Motor with a EtherCat Drivers  3phase Units
3 X 1.5KW Servo Motors from JSS Motors with EtherCat Drivers 3phase Units with Brake
Would like to know if it possible to configure LinuxCNC to work with these motors and drivers
I also have 12 Analog Inputs(Endstops proximity endstops)
Also have a 32Inch Touch Monitor 

So first and foremost can I go the LinuxCNC route
what is  the best recommendations

I looked into ethercat options for i/o and found many different modules at many different price points. Because there is so much aviable prices are not too bad. Its also easy to connect more i/o to the ethercat chain.

With the 7i96s I have a smart serial aviable for expansion cards but its only one port. Multiple boards, I think need to be daisy chained, dont know how to tho. 

The atc will be controlled by pneumatics. If you mean the rack/magazin I will try to design a semi active one, similar to what Marius Hornberger built for his hammer cnc. There will be a rack that moves out of the way when not in use. I plan on making mine not purely mechanical tho.

I hope people already did similar builds and I just need to connect the dots, basicly taking parts I need to make a build out of it. Playing around in the dark is not exactly my aim. 

Since you mentioned price sensitivity, you might think about IO - both current and future needs.

Ethercat drives generally have onboard IO available which can be used as general purpose, but these aren't directly expandable without adding more drives.  Nor can drive onboard IO drive high-power outputs directly - you'll likely need some relays (or similar) to turn on pumps, air cylinders, etc.

If you need more IO than the drives offer you'll need to add an IO module, such as a Beckhoff or other vendor.  Or go with non-realtime IO based on some USB solution.

I haven't priced Ethercat IO modules, but I suspect they are more expensive per IO point than Mesa.  It might be instructive to set up a spreadsheet with all your current and future IO requirements and price out an Ethercat solution vs. Mesa.

Or perhaps both Ethercat and Mesa - this is also an option.

Another consideration is your (future) ATC - have you thought about how to control it?  Will it be a 'dumb' motor using a geneva mechanism, or a servo-controlled thing with a reudcer?  Or something else?

Reason I bring this up is that it might be helpful to find an example of an LCNC configuration which matches your intended hardware...are there any examples of an ATC using Ethercat available, or will you need to break new ground?  Same goes for your possible laser.

It all gets rather complicated, doesn't it?

The Fanuc A06B-6102-H211#H520 spindle module, the A06B-0855-B102 SVM3 A06B-6080-H304 spindle motor, and the A06B-0141-B077 1.0 kW 2.5A X, Y, and Z axis motor, model alphaC12/2000. Thank you.