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Update,

Earlier, the HALUI was not loaded, so I was not able to find the feed override pin in Halshow. Now I have added the section for HALUI and the corresponding pin (halui.feed-override.value) of the feed override is visible in Halshow. But this pin is OUT direction, which means not writable or can not change its value for testing in Halshow only. Attached is one image of the pins available under the feed override tree. I am looking for a pin that takes input and changes the feed override. kindly help! Or share the sample .ini and .hal files for the same purpose

Hi folks, 
i got a problem in a linuxcnc mesa card configuration. if the encoders of the 7i77 counts for a while, the 7i77 lost connection and linuxcnc stops working. Its not possible to calibrate the connected drives because it is not possible to drive more than a few cm before the error comes up.
If the error occurs the green flashing led on the 7i77 turns to constant red and pin hm2_5i25.0.write.time did not change anymore. LinuxCNC itself did only responds very slowly, the rest of the os is working normal. On closing i got an timeout error from linuxCNC.

I think the problem is related to the preempt kernel.

I retrofitted about 20 different machines to linuxCNC with mesa cards custom panels and custom HAL components and i got 2 configurations that shows this error. The configuration system i build to analyse the error consist only of the live image (2.9.4) and 6i25, 7i77 and an encoder.
what did i try so far without a positve result:

• tried 2 different pc with different mainboards (Biostar B450MH, ASUS Prime A320M-R), ram, ssd and graphic card
• tried different 7i77 and 6i25 cards
• tried different encoders (5V, 3V)
• tried debian bookworm and debian buster (with PREEMPT-RT)
• tried different jumper settings
• tried different firmware on 6i25
• tried different encoder inpust
• changed configuration string
• verified that latency is not the problem (less than 50000 servo thread jitter)
• verified that its not triggered by the mesa watchdog (set it to 10seconds)
• viewed the journalctl logs (no hints occour that relates to the problem)
• viewed linuxCNC debug output by running it in the terminal in max debug-level

what i tried with positive result:

• the problem did not occur on debian wheezy 
• the problem did not occur on debian bookworm with rtai kernel
• the problem did not occur on all mainboards

Mayby this is a kind of a solution but it would be the better way, to find what of the preempt kernel causes the problem i quess. So if anyone has an idea how the problem can be solved, please feel free to answer the post.


 

Well no luck with this setup
My friend was trying to cut a piece. The torch didn’t fire up for some reason. The machine started moving without the machine torch on. He stopped the job then tried to jog the machine to the starting point but there as an error and he kept pressing the keyboard without taking notice of the error. Linuxcnc froze then and we tried to kill it but no luck. We rebooted the machine. Now whenever we click on the enable button the esab machine jolts and generates an error. The machine is now unusable. If you enable the estop the machine can be enabled but when you try to jog you get the estop error. We have disconnected the esab motors from the mesa but no luck. The z is still working fine.

have you edited the Arduino sketch as well?

there is only one encoder defined:

github.com/zmrdko/3DWorks_EasyCAT/blob/m...orks_EasyCAT.ino#L93

lines 98 and 120/121

Are the Mesa boards wired directly to the PC?
meaning no switches or hubs or routers or access points.

BIOS password and sudo\root password are unrelated.

The sudo password will be the password of the user you are logged in as.

Just to make sure, the ISO file just hasnt been copied to the USB stick ?
What size USB stick are you using ? I've seen some older machines that have trouble with larger modern USB sticks. I'd try and dig up a 2gb or 4gb USB stick, just in case.
Also some BIOSes, older ones again, have a selection where the USB stick can be selected as a CD-ROM, HDD or floppy drive, if this is the case you may have to play around with this.

Also it would be helpful if you could identify the computer, this info should be available in the BIOS. Some machines\motherboards have quirks that can increase the difficulty level to get simple tasks done. The more info the better we can help.

No idea why packets are being dropped, its unlikely that you have two bad Mesa cards
(and its an odd symptom) 

Didn't you have another PC that did not drop packets?

I would not expect any packet loss even in weeks of operation, here's 10 minutes with a 7I96S

peter@peter-HP-EliteDesk-800-G1-USDT:~/linuxcnc/configs$ sudo chrt 99 ping -i .001 -c 600000 -q 10.10.10.10
PING 10.10.10.10 (10.10.10.10) 56(84) bytes of data.

--- 10.10.10.10 ping statistics ---
600000 packets transmitted, 600000 received, 0% packet loss, time 599999ms
rtt min/avg/max/mdev = 0.105/0.108/0.208/0.003 ms

 

Ive done exactly that , Bios was set accurately , but it still would not boot from the USB Stick. I also must not have root access. The Bios doesnt show a password installed ., but if i use SUDO in the terminal , it asks for my password ?

I am only using Intel network adapters now since struggling with Realtek.
I think you will find it is much better, but not completely gone.
 

if the testgui works, the hardware and gateware should be ok.

the c/riocomp.c must always match the gateware.
so if you have made changes to the config.json and start your LinuxCNC GUI on a different computer or from a different directory, it cannot establish a connection because the protocol no longer matches.

another reason may be that linuxcnc is trying to connect to the wrong IP.

you can look in the riocomp.c to see which ip is there:

#define UDP_IP “192.168.11.194”

and check in config.json whether UDP is really being used:

"protocol": "UDP",

I still have a weird issue that I am thinking is my hardware somehow, I can connect in the test GUI, see inputs, quadrature encoders and toggle outputs, but the terminal window keeps saying received data have wrong header. I have triple checked pins for conflicts. Apart from the terminal spamming that message it seems to test OK. 
Unfortunately LinuxCNC won't get out of estop, and spams wrong header size.

I am still treating it as my hardware, going to setup a different PC, I took out the Tang Nano that is in my milling machine and flashed it but the fault persists. If not the PC, I'll start swapping out PCB's from my two working machines.

Worst part is it was all working nicely last night.

Update,

I have successfully added the emergency stop button. The problem was with the Mesa 7i95 board's nomenclature used for input/output pins. I was using the wrong pin (hm2_7i95.0.gpio.000.in). The correct input 00 pin for the Mesa 7i95 board is inmux 00 pin (hm2_7i95.0.inmux.00.input-00). Below is the code added to the hal file...

net estop-out iocontrol.0.user-enable-in
net external-estop-in hm2_7i95.0.inmux.00.input-00 => iocontrol.0.emc-enable-in


The next problem is still pending about the feed override.
Thank you, Benb and PCW, for your input. You are correct that I want to control feed override using external analog voltage control (cRIO-9045, NI-9775, LabVIEW Software). I have never modified the Mesa default pin configuration, and I am trying to search for how to modify the Mesa board pin configuration. It would be great if I could use the motor or encoder pin for analog input. I request that you give me more ideas/references to do the same. As PCW suggests,  "The 7I95/7I95T has no analog input, so an encoder is probably a better choice." Kindly give more hints on how to use the encoder to control the feed override using external analog voltage control (cRIO-9045, NI-9775, LabVIEW Software)

Another idea I am thinking about is serial communication using the serial port available in the Mesa board; there are two serial communication ports (serial 1, serial 2). But at the moment no idea how to do this as well.

Another thing I was trying to identify was the pin/parameter that is responsible for feed override. In Axis GUI, there is a button for feed override, but I am not able to locate the corresponding pin and parameter in the Halshow Configuration window. I do locate one pin, but it is saying it is not writable. A screenshot is attached.

Thanks

was my mistake, normally I give a warning/error if a pin is used twice, but I had once installed that you can use input pins more than once and forgot to check if both pins are marked as input.

is fixed in dev branch

Hallo ich habe den Test an 2 Verschiedenen Mesa ausgeführt

My first guess, with a quick lock over your files, is that you mentioned directly in the beginning that its an non CIA402 conform drive.
So my first question is why did you use CIA402 in your hal?
Maybe you should connect each PDO which you need from your XML with the correct hal pin over lcec so that you always connect with the right pdos. With the CIA402 you cannot really say...

For your info i bought the ES580 with a Lusintun Spindle and i will go nearly the same path with the Ethercat board, so maybe we will find a solution together...