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What tommylight said.

main.hal:31: Pin 'hm2_5i25.0.7i77.0.4.analogena' does not exist

The channel 4 above makes no sense (on a basic 7I77 configuration the analog channel would be 1)

Correct..do not use spindle control.  Eliminated those sections and references.  CNC now starts until encountering the axis.ngc file for the splash display which is XYZ coordinates instead of XZC. So, struggling trying to replace the file with my old splash file which was in XZC coordinates.  The file is in a read only root directory (usr/share/images/axis.ngc I believe) and I have not yet figured out how to paste in the new file.

In any event, considerable progress and light at the end of the tunnel.  

Thanks so much for the assistance and accommodating my limited competence in LINUX. 

I just watched your YouTube video on you high speed ohmic and it’s impressive. I’m sitting at 20”/sec starting at 1”. I tryied 50”/sec and I seamed to tap the sheet hard enough to float the torch up a smidge which is unacceptable as I normally use small 11x23” sheets of thin material and that hard of a tap can shift them. Abd these sheets are quite pricy at $200-$300 each. I would like to speed it up but if I can’t then I understand. Here is a video of the test cutting. Any recommendations? 

oh and one other question. I only have one switch on each axis for the home/limit switch. In the past I just used them as limit switches but on this install I used them as combination home/limit switches. So now I can auto home the system but once it homes the first axis it stops moving because it thinks it reached the hard stop switch. Is there a way to program in a retract off axis after homing so it does not trigger this hard stop alarm?

1, I set up a number of these drives about a year ago, going from memory, the 5v/24v switch is only applicable to the drives step/dir pins. I am pretty sure I used 24v for the enable input and the error outputs.

2. see #1

3. You could combine the alarm signals, but then when one alarms you won't know which one without opening the cabinet and looking at the drive's leds.

4. With the drives homes wired independently you can do simultaneous homing. With limits separate you can tell which joint is on which limit. (Sometimes this isn't obvious if multiple motors are close to their limits or if you have a wire or switch failure.)

5. ? There's more than one way to do this. But I usually had both an estop out and in to the control to include in the loop.

6. You only need one input for a probe.

AFAIK those breakouts do not have a 5V regulator, you must supply 5V.
So the behavior you see is pretty much as expected. That is, the 5V side is being
powered (weakly) via the PC parallel port data pins.

The regulator just supplies the inputs and the analog spindle interface
(regulates to 12V)

" I can manually force the servo back and forth a bit, and it returns to the same incorrect position."

ok, that's weird. hmm. time to contact lichuan and see how good their support is?

Browsing the web for CNC gear made me fall over this board from Rocketronics.
Couldn't resist so I ordered a board
Micropod1  
Harware is 25 EUR , including Beamicon2 Basic software (However I hope it can be ported for LinuxCNC in some way) <

brief overview of most of the features:

PC software "Beamicon Basic" included, no extra licence costs!
Professional hardware with high interference immunity
With network interface for stable and interference-free data transmission
Connection also via network switch, direct connection to PC not necessary
Fast 32-bit microprocessor generates motor signals independently of the PC
Robust real-time timing, clock frequency up to 1.6 MHz (all axes simultaneously)
Operating voltage 5V
Outputs for 4 axes, X, Y, Z and A
6 TTL inputs (5V) e.g. for reference switches, 1 of which for emergency stop
4 digital TTL outputs, one of them PWM output for spindle control
Supports current reduction and status signal of the output stages 
With pin header socket










 

XXYZ must have 2 home switches for X, otherwise it wont work.
To have both X joints with a single home switch, you must use a normal XYZ configuration that outputs X steps on two outputs. This works fine, but can not do gantry squaring if required.

can you share the AXYZ_connect.hal file?

Ok, then i probably do not understand homing.
This is a cartesian gantry with XXYZ. The two joints for X cannot move separately. So my thinking was homing should be done for the axis instead of the joints; with only one homing switch for both joints (the axis).

Any shortcomings you need a hand working through?

havenofish , That is mm. It happens on Y and Z. I'm not playing with the Xx gantry axis at this point.

Darium, It is within the amplifier as far as I can see. LinuxCNC is sending the correct target position, and the machine is actually where it says it is, but it MAINTAINS a random (small) offset I can jog it around with the pendant and the offset stays the same. I can manually force the servo back and forth a bit, and it returns to the same incorrect position.

Upload pictures of wiring here on the forum so we can have a look.

You have tandem joints/axis so only after homing it will show axis.

Sorry for this newbie question: How do i change the "Manual Control" tab to show the Axis instead of the joints?
Tried in [DISPLAY] GEOMETRY = XYZ, but that didnt work.