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Thanks Hakan,

I followed that thread and tried to test hy_vfd with via halrun but still got the same results. I know the adapter is good as I was using it with Mach3 however, it required a driver and a plug-in to work. I've tried to find a linux driver for the adapter without success.

I decided to purchase a new adapter from Silicon Labs. I've downloaded the linux driver and have attempted to compile and install it. This has lead to much frustration as not all of the <include> header files are in the expected directories. To resolve this issue I renamed the original /usr/include/linux directory to linux_orig and created a new linux copying all of the contents of the linux_orig directory to the new directory then adding the missing header file to new directory in their expected locations. This resolved some issues but surface others.

To resolve the issues, I've added an additional -I path to the /usr/src directory where all of the linux realtime headers reside to the Makefile without success.

Not sure I can resolve this issue at this point.

Does anyone know of an adapter that works with hy_vfd natively?

after editing the PNCCONF according to kworm - update 
forum.linuxcnc.org/39-pncconf/56464-mesa...thcad-pncconf-screen

is possible to configure the step-dir spindle in 7i95T

Could you post the G-code that is giving the error? Not necessarily the the entire G-code program. Especially if the program is large. Just a snippet that includes at least a few lines before the error, and a few lines after, so we might be able to test and reproduce the error. It's a little hard to see and understand what is going on just from your image.

The error joint2 limit error is not caused by your hal or INI settings.
It results as it tells you, because the movement in line 11 will exceed the soft limits.

As you mentioned, that will happen more often with long tools, as your code will use a length compensation for tools.
If the preview window is updated, you will see that limit violation too.

Try the following:
- Change to the longest tool.
- set Z axis to cero on the top face of your workpiece.

Now it should work. 
 

I did a complete re-install and made sure I selected the right board starting config, and now everything works as normal. I must have accidentally started with a tangBOB starting config instead of the TangNano9K, or something along those lines, so as I was re-installing linux/checking hardware I brought the problem along with the original JSON file every time I tried fault finding.

If nothing else I can serve as a bad example !
Cheers.
Russell.

160i is what i recall from the naming on the console, it was made in 2012, again i think, as i do not care much about such info when tasked with making such things work.
I will update info whenever i get a chance, as the stress is gone so now i might also do a less shaky video.
I said "i might" ...