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I think we would need a better macro photo to tel if that was a fatigue failure or not, but it leads me to be rather suspicious of the motor-to-shaft alignment and mounting. Is there any type of flex-coupling there?

Pretty.

Looking at the code around taskintf.cc:976 that error indicates that EMCMOT_JOINT_ERROR_BIT is being set. Have you tried tracking down what might be causing that?

Short answer:

My Powermax is paired with a THCAD-10.  I changed it to 20:1.  It’s served me well with no issues over the years.

Long answer:

forum.linuxcnc.org/plasmac/39999-thcad-1...powermax45-xp#181612

ContinenteCNC wrote:

I wonder if there is a way to force these Sunix cards to load parport_pc driver and module from the I/O ports address?

So it will showup in dmesg as a proper enumerated parallel port.

Why?
I had two of those, both showed everything on 2 different PC's, but 1 did not show driver and kernel module on a 3'rd PC. Same card did show on 1 PC and did not show on another PC.
On the PC that did not show modules another PCI card did not show modules loaded, after showing them and working for years.
All this points to something in BIOS causing that, but i am out of luck as i can not find any more of those Sunix cards.
Here is one example of it showing modules loaded
forum.linuxcnc.org/10-advanced-configura...uing?start=20#324494

As to why adding 16 to the mode doesn't work...

I guess that the problem comes if the orient.0.mode pin is connected to spindle.N.orient-mode, I didn't realise that the P number had a limit check on it.

If it is controlled by a "setp" in the HAL then it should be fine (with the spindle.N.orient-mode pin left unconnected)

That means that you can't change the mode with the P command in M19. I don't know if that is really a problem, though?

It depends on your machine amperage. No scaling resistors are rwquired. Most people use 20:1 which gives a 200 volt full scale, 125 amps might be better at 30:1. (300 volts)
The thing is that the THCAD is rated for overvoltage of 500 volts. The voltage will only go over 200 volts on piercing when we do not care about the voltage then. During cutting voltage is between 100-170 volts. Keeping the max voltage range low means the readings are more accurate as more of the ADC's range is used. 50:1 is popular with a lot of non-linuxcnc THC's  (probably with a 0-5 volt ADC). That would be better for a THCAD5.

HOME_SEQUENCE = -1
on both your Y joints is needed. Refer to homing configuration in the docs.
Sometimes you need to invert the sign of the LATCH_VELOCITY to make it go the right way.
 

Yes, almost at the bottom:
AttributeError: Handler hal_button_pressed not found

So, in your .ui file there is a button that triggers the event "hal_button_pressed" and no handler for that event in the python.

Looking through the .ui file in a text editor:
in the Python I see:
So you have written the handler, but in my editor the entire code body in the Python file appears to be triple-quoted (lines 15 and 120) and is highlighted in red. It may be that this is causing the whole handler file to be ignored.

Yes, there is no non-volatile information stored in the FPGA.

Have you connected the index-enable to the PID? That is intended to prevent a PID "bump".
pid.N.index-enable
linuxcnc.org/docs/stable/html/man/man9/pid.9.html#PINS

Cool, the ISO install points that file to the Linuxcnc.org repositories so deleting it let it us overwrite it to use buildbot2
Also we have a preferences file we delete to ensure Debian chose the Linuxcnc version at Linuxcnc.org, not the obsolete one in the Bookworm distribution. I don't think we need that here because  version 2.10 is > 2.94 (it worked for you)
If we do, we can edit the saved preferences version from the apt folder in your home folder or get it from the linuxcnc-livebuild (the binary versions are what we use, chroot is just for the builder)
github.com/LinuxCNC/linuxcnc-live-build/...worm/config/archives

Finally, I might add that this install is not best practice for apt. If you look at the Ethercat list.binary file, the key is explicitly referenced in the Deb archive line

As Andy says, the error is from Linuxcnc core, not the GUI.
I would be running the probing from probe basic and not get F360 to do anything with the probe (I didn't know you could)
I've used a probe with F360 and qtdragon and it all worked perfectly.
 

I should be able to just swap that fpga right? Assuming the EEPROM and whatever else is still good.

That worked. Was it supposed to overwrite the content of the linuxcnc-uspace.list?
That's what it did anyway. If you just wanted to add a new line at the end, "tee -a" is the answer.
Considering you did that in the previous commands with echo and >>