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I have a DIY RouterMill that I've been fighting with for many years. I recently ditched MACH3 and paraports for the MESA 6i25 <=> 7i76u combo.
After flashing the 6i25 with the 5i25/7i76u x 2 bitfile and updating LCNC to 2.94 and configuring with PNCConf, all of the steppers worked as expected and were tuned for optimum movements for my machine. Turning my attention to the INPUTS, based on what I understand from the docs, the INPUTS are sinking so I configured the machine with all INPUTS as follows:

VF(24v) -> switch(NC) -> 7i76.0.0.input_nn

After starting LCNC, I notice that the ESTOP was triggered but, the button was not closed. Checking the INPUT pins with halshow, I could see that the board was showing all INPUTS as TRUE, therefore I changes all of the INPUTS to input-nn-not and restarted LCNC. Now all of the INPUTS seemed to respond correctly. When I attempted a HOME_ALL, the Z moved to positive, so I reconfigured it to home negative with PNCConf. That worked and after more reading and adjusting of some parameters, I got the Z homing correctly backing off the trigger position by .050 in.  Then I directed my attention to X.  However, I had to adjust a few more parameters for the X axis then restarted LCNC. *)#$!! All of the inputs had switched and were now reporting as TRUE. Frustrated I changed all INPUTS back to input-00 and restarted LCNC. With this session I was able to get both the Z and X axes to home correctly, however, Y was now the problem child as it would not back off the trigger position. After several attempts I finally decided to swap DIR-/DIR+ at the microstepper so the Y config was exactly as the X config. (My Y axis is at the back of my machine so I had reversed the motor in the config for correct movement). After making the change and while running PNCConf I confirmed that the Y axis was now responding correctly then proceeded to resume verifying  the HOME ALL function, The attempt failed, so I tweaked the HOME parameters but, when I restarted LCNC all of the INPUTS had again switched their state (*)#$!!,*)#$!!). More bizarre was that now no matter how I set the PROBE input (input-nn or input-nn-not) the halshow remained the same.  After several additional restarts, the input pins again flipped the input state.

At this point I'm half inclined to suspect the 7i76 board as it has one INPUT, input-04, that is always stuck in the same status in halshow much as the PROBE input is now responding.

If anyone has any ideas that I can try, I would greatly appreciated the support.

Regards,
Stephen

I use Gmail just like Todd, and there are no emails in any folder.

Hi -- did you have any luck sorting this out? I am not working with linuxcnc, but I am having a similar error with the akd2g + ethercat in ros2 and was wondering if there was a common thread.

If you unplug the Ethernet cable from the 7I96S, do any lights on the RJ45 connector illuminate?
If so, this indicates ESD damage to the 7I96S's Ethernet port. This can only be repaired by replacing
the Ethernet chip.

To avoid this kind of damage, it important to ground the chassis ground on the 7I96S to earth ground.
 

rtt min/avg/max/mdev = 0.085/0.161/3.281/0.042 ms

is better but still not good

Take a look at this thread, especially the kernel command line (setup with grub)

forum.linuxcnc.org/18-computer/56380-error-finishing-read-sigh
 

There’s a diagram in the previously provided link. No resistor for the reed switch.

I tried a resistor and no luck with the contact. I'll give Tommy's reed relay a try. Does it matter where it is in the lead and should it need a resistor?

Yes, LinuxCNC supports backing off of the limits, be it hard or soft, it has a button for that in the GUI, but :
-you never mention any info about the machine, like it uses EtherCAT
-i have no experience with EtherCAT, so no idea if normal LinuxCNC stuff applies to it
-you keep asking for help, but still fail to provide info, this is frankly agonizing
-you posted twice in the wrong sections, there is EtherCAT section on this forum, but this is not important as we do not mind moving topics around, and i did this once, now i have to do this again as you did not provide the info on the first post, nor the second nor....
-
In general, limits should never be crossed if everything is set up properly, and that is easy to achieve, but this is EtherCAT, so i am moving this there, much more experienced users there so should figure where the issues is.
I would venture a guess at setting some small HOME_OFFSET in the ini file, like a mm or two, so even when you disable motors they could not reach limits. Maybe this is all you need...

So you are saying that Linux CNC supports jogging back into soft limits? 

config attached

Hallo
Realtek DKMS-Treiber. installiert.
Test
60000 packets transmitted, 60000 received, 0% packet loss, time 60021ms
rtt min/avg/max/mdev = 0.085/0.161/3.281/0.042 ms

tommylight wrote:

Much better to post more info about your machine and how the homing is set up, and uploading config files usually helps a lot.

I have absolute encoders and thus don’t home. Though through other posts it does not seem that is well supported.

I thought this would be a quick answer. Does Linux cnc not have the ability to jog to get back within soft limits? I would expect the that can’t jog more into the limit but you should be able to jog out of the limit. Is this supported?

After some trial and error, I got it kind of working.

The wiring:
SPIN+ 9
SPINOUT 1U
SPIN- 7 and GND (you need to pass GND from your Field Power to 7 at the application I/O Modul)
ENA+ VField (+24V)
ENA- 28
DIR+ VField (+24V)
DIR- E4 (digital Input, reverses spindle direction if "HIGH")

cave: the application I/O has two Inputs labeled "7". They both need to be connected to GND (they are not connected internally, so you need to bridge them).

The only Problem I have left is the scaling. As far as I understand it works like this:

"hm2_7i92.0.7i76.0.0.spinout-minlim" is set to the minimum RPM I want to allow linuxcnc to pass to the VFD. In my case I set it at 6000 (any slower and the spindle tends to stall)

hm2_7i92.0.7i76.0.0.spinout-maxlim same as "minlim" but with maximum RPM. I set it at 24000, so everything above S24000 is ignored/capped at s24000

hm2_7i92.0.7i76.0.0.spinout-scalemax the theoretical RPM call, that would tell the MESA card to pass the full SPIN+ Voltage to SPOUT.

So I set it to (5,2/5)*24000 = 24960. That does not seem to work too accurate. If I plot the set Speed (via S... command) and the frequency at the VFD, I get something that I would call "good enough for my hobby", but "wrong" enough to question my understandig of "spinout-scalemax".

I will try to post the graph I get in a separate reply. Are my thoughts on the scaling correct that far, or is there an error in my settings?

Yes it works for me.
However right now, i do not yet have the actual machine ready, only the servos mounted next to each other on a piece of chipboard.
I can home and run the "demo" that comes with Axis Gui.

Any progress so far? Did you manage to do internal homing cycles with the A6?