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Thanks so far for the information.
So first step is to ask the cnc.step guys if there is a config file for linux cnc for their machines.

After that (assuming it is more likely they don't) I have to guesstimate which way is more painless:
-how to get a working LinuxCNC machine, which includes some hands on hardware building and embedded software back and forth
-using the cnc-step machine with windows software to run it with the pain included by that. That would be the first windows PC to be administered by me in about 20 years. Which might be even more pain than the above (at least for me).

What about 100-120mb programs? Are they possible? LinuxCNC seems to crash then loading those.

Just my take on it. There are many ways to run linuxcnc, keep that in mind.

My questions:
* What should I run LinuxCNC on?  I've got a spare RPi 4 sitting in my drawer.  I've got a couple of Supermicro Intel Atom-based ITX server motherboards lying around.  What's the most intelligent way to go?

Atom is probably below the acceptable performance limit, but anything faster than that. There are some new mini-ITX main-boards with N100 integrated. CPU performance is more for the user experience, the later HMIs (or guis) may need a bit faster CPU, while the old Axis works with anything. For the cnc part it is about real-time jitter and there usually are ways to tweak settings to come to low jitter. I go with N100 nowadays, but its just one of many possibilities. Once you have seen the newer guis you will want to use one of those. And need at least some CPU performance. I ran on RPi4, I would think a step up to RPi5 would be nice.

* It seems that a parallel port interface is the "old-school" way of doing things.  Now, it seems that most prefer an Ethernet interface.  Is there a disadvantage of going one way or another?

Stepper performance (steps/seconds), number of IOs, and other types of IO than digital IO is what makes people move away from the parallel port. Plus that main-boards nowadays seldom have a parallel port and need to have one added.

* Since I have to replace the steppers anyway, is it foolish to go with a "traditional" setup rather than Ethercat?  It seems like Ethercat will be considerably more expensive (like twice the price or more) - but is it worth the price?

You won't get anything extra from the milling machine using EtherCAT. It is a different way of doing the same thing.

* Everyone seems to agree that Mesa boards are the "gold standard."  How do Pico Systems' boards compare?  Jon Elson lives like 20 miles from my house.  Does anyone have experience with his customer service?  Is it foolish to consider anything other than a Mesa?

From what I can see, and I may be wrong, the Pico Systems' board connect to the parallel port? If you go with a parallel port solution that can work. Mesa's board on the other hand typically use EtherNet, SPI, PCIE, or PCI (and maybe more) to connect to the computer. This gives speed and reliability.

* If I go with a Mesa setup, which direction should I go?  If I use the RPi, I could go with the 7C80 or 7C81 - I could also run an Ethernet setup.  If I use the server motherboard, I could go with a parallel port setup or an Ethernet setup.  Is there an advantage of going one way or another, here?

I've only used Ethernet setup and see few reasons to do anything else. If you are only ever to use Raspberry one can think of the 7C line. I would like to keep all options open as far as possible.

* If I go with a given Mesa board, what else will I need to buy?  It seems that some of the Mesa cards (like the 7C80 and the 7I95T) will hook directly to the stepper drives, while others require a separate daughter card (BoB)?

Send Mesa a mail with those questions, they are usually very happy to help. For a normal stepper motor system I would look at 7i96, which connects to the stepper driver with the step/dir/enable signals.

* What hardware (if any) would I need in order to use the encoders on the steppers as a DRO?  Will any of my hardware selection above affect my ability to have this feature?

For Mesa to answer, I think you are looking at a 7i85. From what I understand, encoder counting is done by the FPGA, so the card must either do it itself on the FPGA board, or have a connector that allows a daughter board to connect the encoder inputs. The 7i96+7i85 does that.

* Will a cheap Amazon/Aliexpress stepper motor/drive/power supply set work, or will I need to buy the stepper drives separately?  If I need a particular stepper drive, should I go with a Gecko or something else?

Yes, will work fine, just size it to suit the stepper motors. I have good experience with such stepper drives.

* If I run a touchscreen and a pendant, is there any reason why I will need a keyboard hooked up to this machine (once it is configured)?

Depends on the gui and how well touch screen input is integrated. For example, I run the qtdragon gui and there the keyboard input is well integrated. Except when I need to edit the G-code file, then I bring in the keyboard. Normally I have it tucked away though.

The linuxcnc support is the big question.
It is neat to buy a ready-made box but you still need to have a place for stepper motor drivers so it is only half the solution.

Gents,

I'm slowly preparing items and knowledge to make my plasma cutter based on Hypertherm Powermax 45 XP (just received CPC port upgrade kit). I have a specific conditions - at work for 4 weeks and away from home/garrage and i could only take limited set of toys with me:
- Lenovo T470 with Linuxcnc installed
- Mesa 7i95T
- 2 x THCAD (for THC and ohmic)
- some limit switches
- 3 x H-bridge and 3 x small PM DC servo motors
- bunch of wires
- old laptop power supply to power those servos.

That's all i have to play with LinuxCNC and learn configuration, etc. Ideally i'd like to make those servos live on my bench.
I couldn't take "real" servos and drivers due to weight limitation - my only option was to take those small servos and h-bridge modules. 
If i understand things correctly, out-of-the-box mesa cards are preloaded with firmware containing Step/dir generators and can't be used to control -bridge based servos it this state. So i need to build a specific firmware to replace step gens with pwm generators, right?
I'm stepping here into very dark area for me - creating custom bit file.
I heard that custom bit file are now easier to create with the new FPGA chips on Mesa cards - is it true?
I case of my failure - would it be possible to get some help from you to create custom bitfile? The only source i found is talla83 videos on yt.

Thank you for inputs and have a great weekend.

Thanks guys. I ended up taking T470 with touch screen. Added Linuxcnc along with already existing Win and 7i96 works with no issues (on the table for now). Just received 7i95T today to have some fun but this requires some deeper tweaking - for separate topic. Thanks again - computer topic solved for me.

HI Tommy,

Yes it did. The week before I had a loose screw rattling around in  in my pendant cause a short, which tripped that fuse. I removed the screw and reset the fuse.

Hi Peter,
With only CR8 lighting up (steady) with this 7i84 plugged into its SS cable, and field power disconnect, is this board worth soldering new output IC's onto, or is it pining for the fiords dead?
Cheers,
Mark

Can Phill or Snowgoer have a look at this issue? Sorry I thought it was wider than QTPlasmac but further testing shows it only affects QTP.
forum.linuxcnc.org/9-installing-linuxcnc...-on-buildbot2#324519
This is on a SIM only and I need to upgrade a live config
Thanks

Ooops, this is QTplasmac specific and that is jut opening a Sim already on my PC. But I do need to edit a live sim
 

I adjusted the apt settings so Debian gets  the buildbot2 deb file for LinuxCNC V 2.10. 
The upgrade of linuxcnc was sucessful.
When I open a config from the consiole, a window appears that says 
Updated to V2.10-001.017, Due to Configuration a Restart is required
I open the config and I get the same error
I reboot and I get the same error
I though tthen to check the ini fil to make sure it is not read only. It was so I updated the permisssions to write to it.
But I still can't open any config,  

How do I resolve this?
 

You could get rid of the short and try adding an isolated 24v power supply (Meanwell hdr-15-24) that is connected to the plasma inputs on the thcad. When cutting, nothing will get damaged. The hypersensing component can see full torch voltage when you are cutting  and it does not care... so this should give you the confidence to do it

You might need to and2 the probe signal so it will only turn on when actually probing.

mclien wrote:

rodw wrote:

My recommendation would be to buy a Mesa 7i96s and do it yourself. You will get a better performing machine, probably for the same money without limitations from the parallel port
 

 
Well. do you mean to only use that controller and the mentioned machine or use the Mesa 7i96s an build the cnc hardware by myself?

Build it yourself. For starters, it appears your box uses 24v power. Running them with a 48v power supply from 7i96s will near quadruple motor  torque.
I doubt Linuxcnc is supported via Ethernet.

Here is a quick test where I jumped the shield to the nozzle and then feed voltage from my ohmic into it and then ground the nozzle and the voltage drops like a stone. My thcad-10 is using opto22 and relays to isolate everything so that’s why I have to trigger the ohmic button to send voltage to the nozzle.



youtube.com/shorts/fuJnQ76LXl8?si=pr583jeB8bvqNj0g