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1. check wiring, literally remove each wire and re-seat it properly on the THCAD side and BeckHoff side
2. use a DVM with memory min/max and measure the 5V supply for the THCAD, if it goes under 4.75V change the power supply or add a 100-220Ufarad capacitor at the THCAD terminals and test again
3. set the divider higher or lower depending on how you look at it, if it is 1/32 set it to 1/64 and plot again.

Will do tomorrow and post the results!

Yes, much better! Buy a serial port to RS485 adapter rather than a USB one.

Aussie link for example
core-electronics.com.au/rs-232-to-rs-485...hSu9V9RoC41AQAvD_BwE

Yes, a rack would be easier for sure and save quite a bit of time, debugging and possibly issues.
But would I extend the work area, I still don't want to lose 10cm to the rack.
Also due to exponentially increase of the risk of ballscrew whip, I don't want to go bigger than 2000mm on the screws, which means 1840mm of work area after extending +200mm.

It's just my application, probably for most other people it would be fine to place the rack.

Construction wise, I only shifted the X beam about 5cm from the current symmetric configuration.
It wasn't easy to design but there is room to do the toolchange outside of the working area and still reach the full width with the mill and probe.
One issue I have to solve is the retractable probe is entering the work area, so I will change that later on to a different construction not protruding, with two carriers,

 
 

Would only be an issue if I put something on the table which occupies the whole space, like a huge block of foam.

Though perhaps I should have started at the beginning:
Install the correct Pi image from here:
www.linuxcnc.org/downloads/

Hi, to be really honest, this line came from ChatGPT, but indeed, I am still trying to understand where this comes from . Didn't found anything in the docs describing this include thing. What I am trying to do is to pass a variable from a macro (state of output pin) to a subroutine. Since subroutine variable can only be flaoting points, I changed the VALUE in the macro to be 1.0 if if true and 0.0 if false. Now the macro does work, however the subroutine gives the error message that there is a wrong command in the subroutine.... must indeed be the 'include' thing

Getting the ENA signal out to the original Hurco servo relay was problem as they draw 55mA. Solved by using a ULN2003 channel. Note that this needs to be done via a series 3k3 resistor and 1K resistor to ground.
Re the Estop.
I can trip the Estop relay, from the GUI, or pressing the Mechanical button, however, when I use the Mechanical switch, the gui doesn't register that the relay has tripped.
Is it possible to use the fact the estop terminal (OUTPUT0) is no longer conducting as a signal to change the GUI Estop status? If that's not picking myself up by my bootlaces...

Hmm. Seems I cant really do much without having the drives here. But how deal with the rs485 for the spindle?

I see some people using usb adapters, but I have a real serial port as well, can that be used instead?

Well, to get a basic config and axes moving, I would suggest running the pncconf wizard. (though I don't know for sure if that supports the 7C80)

Even if it doesn't you can choose a different board and at least get the required config files set up in the folder structure, even if the details of the board name are not 100% correct.

You might find some useful ideas here; forum.linuxcnc.org/30-cnc-machines/42100...up-questions?start=0
I wrote (most of) a special purpose system without any G-code for a press brake.

GladeVCP and Python is probably the well trodden path, but QT and C++ is certainly possible.

And you will need C for any realtime parts such as custom HAL components.

This suggests that something (like a remap) is calling a bit of G-code with the letter E in it.
Or possibly there is something in your actual G-code file that is making it see an E as a command?

yeah this implementation has been a long time coming, it wasn't a small undertaking and is still a work in progress, but it should really help users get going! pretty jazzed about it!

I would run an apt update to make sure you are on the latest probe basic to ensure your sim config contains the most recent updates

the user parameters require the var file to have the numbered variable listed in the file, this makes them persistent, if they are not in the file they are volatile which will work if entered in the ui for that instance but not be stored. the ui also has a settings storage method and this can become unsynched if the var file is missing the listed parameter numbers. it is an issue we are trying to resolve but as long as everything is in place it works as expected without issue.

the subroutines contain update parameter subs which are responsible for writing the newly ui entered parameters to the var file. so those need to be in place too!

is there enough cushion on the opposite side of the X extrusion to slide everything over enough to have a tool rack on the outside of the left side gantry upright? or maybe consider the cost comparison/complexity to be able to add a longer set of rails and a bolt on extension to make that possible?