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Had an idea, dangerous I know!
I put a buck converter on the 24VDC supply to get me 10VDC for a ref voltage for the spindle output. Tested with the buck converter and of course had the same problem but it allowed for another test. Note the spindle out was at 5V then 0V when the spindle stopped.

I powered off the breaker for the VFD and put my meter on the Spindle Out/Gnd. The M3 S9000 (5V) held with no reset. I tried a few different speeds and all worked. It is some type of EMI problem.

Any suggestions on how to resolve this? I have a EMI filter on the VFD. I tried moving the VFD further away from the 7i96s and no effect.

The index signal sent to the encoder input to LCNC must be 1:1 with the spindle. My encoder is on my motor. But, I get the index signal from the sensor on my spindle. If the gearing of the motor to the spindle was exactly 1:1 you could attached the encoder to either the motor or spindle. But if the gearing is anything other than 1:1 you must get the index signal from the spindle. My gearing is 1:1.8 and the A/B encoder signals come from the motor side, but my Z (index) signal comes from the spindle side.

It had no effect removing the xbox.hal and disconnecting the controller.
Something I noticed this time is I changed to qtdragon (from qtdragon_hd) so I could see the terminal window behind. In that change I noticed the "At Speed" indicator beside the spindle controls turns green when I enter the M3 S9000 and when the motor stops the indicator flashes.
The other not so obvious item is the machine 95% of the time switches to "Machine Off" but not 100% of the time.
I also noticed the secure boot was enabled, I thought I had disabled that. It is now disabled in bios.

thank you for your help. I want to ask you a question. I have a mesa 7i96s card. stepgen.00 X axis, stepgen.01 Y axis, stepgen.02 Z axis, stepgen.03 spindle pwm speed control, stepgen.04 a axis. I use spindle speed mode. I turn the spindle with m3 command, then I stop the spindle with m5 command. I want the spindle tip to always stay at the same angle when I give the m5 command. How can I do this?

Nothing too obvious

I would try running without the XBOX controller
USB devices are notoriously sensitive to noise.
 

I bought the version with the most memory. I figured that it was safer to spend a little extra and never run out of memory (which could be fatal).

What this means?
That for rigid tapping encoder must be on spindle shaft
or must be on 1:1 ratio with spindle shaft?
Other ratio configurations can't work for rigid tapping ?

I've been asked not to post any images or videos of the machines publicly, but if you want me to send you some, email me at This email address is being protected from spambots. You need JavaScript enabled to view it..

Ah, I took a look at the actual wiring on my machine. I get the A/B signals from the simulated encode in the servo drive and the Z (index) signal from the sensor that is looking at the slot in the disc on my spindle. That is how mine is able to work.

Thanks Andy

I have done some more investigating.

When I run the initial setup to probe the tool setter and the workpiece, I get
PROBE HT -55.990
BLOCK HT -70.610

Which would indicate the workpiece is 14.62mm below the toolsetter plane.

When I do a T1M6 (without physically changing the probe out) it errors as previously described.

If I move the machine manually to the workpiece height, I get Z70.610 in G54 coordinates. Notably, T1 now has an offset of -70.610 in the tool table.

It seems that, in G54 coordinates, the workpiece top should be Z0.

Perhaps the key is to probe the workpiece and set G54 Z(probe length) before making a tool change...?

Edit:

I am not sure what I did, other than put an M1 before the final return to the previous point.

Here's where I discovered an issue.

If the new tool is long enough to cause the return to point (in G54) to be out of bounds (in G53) it errors just the same.

So, there needs to be some logic that checks if the previously saved tool position will put the machine out of limits. Then, I think there should be a "Z SAFE TRAVEL" variable which the user can set as a minimum height to travel on during the tool change. This would account for the Z0 position not being the same height as the top of the workpiece.
Then, the logic checks to see if the tool tip is between G53 Z(Max) and Z SAFE TRAVEL. If so, move to the XY position at whatever Z height it's currently at. If not, move to Z SAFE TRAVEL then to XY.

I suppose the 'Z_MAX_CLEAR' parameter in the ini is supposed to do that, but it seems counterintuitive to be forced to change it for every new setup.

Of course, if I had a mill with more than 120mm Z Travel, that would probably help...

Hello PCW,
Thanks for the reply. Below is the output from the command line run. There is another error that sometimes appears but not in this run.
AT-SPI: Could not obtain desktop path or name.
I added manual events with ***************** this was not log captured

larryp@2x4cnc:~$ linuxcnc
LINUXCNC - 2.9.4
Machine configuration directory is '/home/larryp/linuxcnc/configs/CNC2x4'
Machine configuration file is 'CNC2x4.ini'
Starting LinuxCNC...
linuxcnc TPMOD=tpmod HOMEMOD=homemod EMCMOT=motmod
iopl() failed: Operation not permitted
cannot gain I/O privileges - forgot 'sudo make setuid' or using secure boot? -parallel port access is not allowed
Note: Using POSIX realtime
Found file(REL): ./CNC2x4.hal
hm2: loading Mesa HostMot2 driver version 0.15
hm2_eth: loading Mesa AnyIO HostMot2 ethernet driver version 0.2
hm2_eth: 10.10.10.10: INFO: Hardware address (MAC): 00:60:1b:16:8a:55
hm2_eth: discovered 7I96S
hm2/hm2_7i96s.0: Low Level init 0.15
hm2/hm2_7i96s.0: Smart Serial Firmware Version 43
hm2/hm2_7i96s.0: 51 I/O Pins used:
hm2/hm2_7i96s.0: IO Pin 000 (TB3-01): InM Input Module #0, pin in0 (Input)
hm2/hm2_7i96s.0: IO Pin 001 (TB3-02): InM Input Module #0, pin in1 (Input)
hm2/hm2_7i96s.0: IO Pin 002 (TB3-03): InM Input Module #0, pin in2 (Input)
hm2/hm2_7i96s.0: IO Pin 003 (TB3-04): InM Input Module #0, pin in3 (Input)
hm2/hm2_7i96s.0: IO Pin 004 (TB3-05): InM Input Module #0, pin in4 (Input)
hm2/hm2_7i96s.0: IO Pin 005 (TB3-06): InM Input Module #0, pin in5 (Input)
hm2/hm2_7i96s.0: IO Pin 006 (TB3-07): InM Input Module #0, pin in6 (Input)
hm2/hm2_7i96s.0: IO Pin 007 (TB3-08): InM Input Module #0, pin in7 (Input)
hm2/hm2_7i96s.0: IO Pin 008 (TB3-09): InM Input Module #0, pin in8 (Input)
hm2/hm2_7i96s.0: IO Pin 009 (TB3-10): InM Input Module #0, pin in9 (Input)
hm2/hm2_7i96s.0: IO Pin 010 (TB3-11): InM Input Module #0, pin in10 (Input)
hm2/hm2_7i96s.0: IO Pin 011 (TB3-13/TB3-14): SSR #0, pin Out-00 (Output)
hm2/hm2_7i96s.0: IO Pin 012 (TB3-15/TB3-16): SSR #0, pin Out-01 (Output)
hm2/hm2_7i96s.0: IO Pin 013 (TB3-17/TB3-18): SSR #0, pin Out-02 (Output)
hm2/hm2_7i96s.0: IO Pin 014 (TB3-19/TB3-20): SSR #0, pin Out-03 (Output)
hm2/hm2_7i96s.0: IO Pin 015 (TB3-21/TB3-22): OutM Output Module #0, pin Out-04 (Output)
hm2/hm2_7i96s.0: IO Pin 016 (TB3-23/TB3-24): OutM Output Module #0, pin Out-05 (Output)
hm2/hm2_7i96s.0: IO Pin 017 (TB1-02/TB1-03): StepGen #0, pin Step (Output)
hm2/hm2_7i96s.0: IO Pin 018 (TB1-04/TB1-05): StepGen #0, pin Direction (Output)
hm2/hm2_7i96s.0: IO Pin 019 (TB1-08/TB1-09): StepGen #1, pin Step (Output)
hm2/hm2_7i96s.0: IO Pin 020 (TB1-10/TB1-11): StepGen #1, pin Direction (Output)
hm2/hm2_7i96s.0: IO Pin 021 (TB1-14/TB1-15): StepGen #2, pin Step (Output)
hm2/hm2_7i96s.0: IO Pin 022 (TB1-16/TB1-17): StepGen #2, pin Direction (Output)
hm2/hm2_7i96s.0: IO Pin 023 (TB1-20/TB1-21): StepGen #3, pin Step (Output)
hm2/hm2_7i96s.0: IO Pin 024 (TB1-22-TB1-23): StepGen #3, pin Direction (Output)
hm2/hm2_7i96s.0: IO Pin 025 (TB2-02/TB2-03): StepGen #4, pin Step (Output)
hm2/hm2_7i96s.0: IO Pin 026 (TB2-04/TB2-05): StepGen #4, pin Direction (Output)
hm2/hm2_7i96s.0: IO Pin 027 (TB2-07/TB2-08): Encoder #0, pin A (Input)
hm2/hm2_7i96s.0: IO Pin 028 (TB2-10/TB2-11): Encoder #0, pin B (Input)
hm2/hm2_7i96s.0: IO Pin 029 (TB2-13/TB2-14): Encoder #0, pin Index (Input)
hm2/hm2_7i96s.0: IO Pin 030 (TB2-16/TB2-17): IOPort
hm2/hm2_7i96s.0: IO Pin 031 (TB2-18/TB2-19): IOPort
hm2/hm2_7i96s.0: IO Pin 032 (internal): IOPort
hm2/hm2_7i96s.0: IO Pin 033 (internal): SSR #0, pin AC Ref (internal) (Output)
hm2/hm2_7i96s.0: IO Pin 034 (P1-01/DB25-01): IOPort
hm2/hm2_7i96s.0: IO Pin 035 (P1-02/DB25-14): IOPort
hm2/hm2_7i96s.0: IO Pin 036 (P1-03/DB25-02): IOPort
hm2/hm2_7i96s.0: IO Pin 037 (P1-04/DB25-15): IOPort
hm2/hm2_7i96s.0: IO Pin 038 (P1-05/DB25-03): IOPort
hm2/hm2_7i96s.0: IO Pin 039 (P1-06/DB25-16): IOPort
hm2/hm2_7i96s.0: IO Pin 040 (P1-07/DB25-04): IOPort
hm2/hm2_7i96s.0: IO Pin 041 (P1-08/DB25-17): IOPort
hm2/hm2_7i96s.0: IO Pin 042 (P1-09/DB25-05): IOPort
hm2/hm2_7i96s.0: IO Pin 043 (P1-11/DB25-06): IOPort
hm2/hm2_7i96s.0: IO Pin 044 (P1-13/DB25-07): IOPort
hm2/hm2_7i96s.0: IO Pin 045 (P1-15/DB25-08): IOPort
hm2/hm2_7i96s.0: IO Pin 046 (P1-17/DB25-09): IOPort
hm2/hm2_7i96s.0: IO Pin 047 (P1-19/DB25-10): IOPort
hm2/hm2_7i96s.0: IO Pin 048 (P1-21/DB25-11): IOPort
hm2/hm2_7i96s.0: IO Pin 049 (P1-23/DB25-12): IOPort
hm2/hm2_7i96s.0: IO Pin 050 (P1-25/DB25-13): IOPort
hm2/hm2_7i96s.0: registered
Found file(REL): ./custom.hal
Found file(REL): ./xboxctrl.hal
note: name is 'Microsoft X-Box 360 pad'
note: name is 'Microsoft X-Box 360 pad'
**************** This is the end of startup before Machine On was pressed, no logged events from Pressing Machine on.
**************** MDI: M3 S9000 - ran about 1 second
task: main loop took 0.124348 seconds
task: main loop took 0.100006 seconds
**************** MDI: M3 S14000 - ran about 1 second - note sometimes it runs for 3-5 seconds but never gets spindle to speed
task: main loop took 0.124488 seconds

**************** EXIT button pressed
qt.qpa.xcb: QXcbConnection: XCB error: 3 (BadWindow), sequence: 31380, resource id: 8630017, major code: 40 (TranslateCoords), minor code: 0
Shutting down and cleaning up LinuxCNC...
Running HAL shutdown script
task: 19007 cycles, min=0.000013, max=0.124488, avg=0.010070, 3 latency excursions (> 10x expected cycle time of 0.010000s)
hm2_eth: in hm2_eth_reset
hm2_eth: HostMot2 ethernet driver unloaded
hm2: unloading
iopl() failed: Operation not permitted
cannot gain I/O privileges - forgot 'sudo make setuid' or using secure boot? -parallel port access is not allowed
Note: Using POSIX realtime

If I understand right you have bit-arrays and need to create individual pins for each bit. You do that with complexEntry, for example like this.Create a close-to-working config using "lcec_configgen".
Debug output including config errors/warnings/info with "sudo dmesg" the last couple of lines.
 

Hey guys, ive just finished working on a homing sequence for my 6 dof robot arm using a puma560 config and its homing perfectly fine except for when the homing sequence is supposed to end, after all joints find their end sensors and drive to the home position, the joints pos is set correctly (in my case 0, 90, 0, 0, 0, 0), the simulator position matches the physical position but as soon as the sequence ends the genserkins position goes to these crazy values and i get a kinematics failure and cant move anything, below ive attached the ini and hal files aswell as a screenshot.

Hi,

share outcome from the command of
and 

then you will be able to create PDOs ...

If slave has DC or any configuration over SDOs - easist way is do it over TC3 - my experiences