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I don't plan on changing anything right now, most of the things I want to add would fit better in the user tab, but I want to know how to modify the main interface if necessary.

The following is block diagram based on BJT Run/Step Hold/Resume Buttons hal netlist file as shown at the beginning of this discussion.
  Now, let’s start little tutorial that show how you can generate hal file from a block diagram:Let’s take the first line of the block diagram and convert it into hal netlisting:
  I let you do the rest as an exercise. Once you get hang of converting block diagrams to hal netlist you will find that it makes creating hal solutions much easier.Now if you would like to automatically generate hal file from block diagram. The one I use is eagle2hal see LinuxCNC wiki or even better use Ed Nisley kicad to hal. softsolder.com/2021/03/25/kicad-to-hal-basic-schematic-symbols/

the manual says it has 1 channel pulse input (33 kHz), 1 channel pulse output (33 kHz), not sure what this is maybe like stepper pulse in. im using 4 channels of the 7i52s for XYZA axis, the A is available for the spindle. still having trouble turning all the step gens on. i got it working before and i followed the forum posts that worked before but i think im doing something wrong. the machine has a spindle encoder, but the manual unclear on how to implement the pulse input. think it would be 1 cw pin, 1 ccw pin, pulse pin (step?) and some kind of enable(run) pin. have a 7i82d that i could put the pins on and use encoder and step(pulse) or pwm out on the 7i52s

Been over 8 month since his last upload, i really hope he is OK.

Added the old youtube channel on the first post, plenty of videos there.
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Rod, i did check some stuff online, was quoted 3200-3800$ just to get a 110KG box sized 3.5x0.8x0.8 meters from the ship to a truck outside the port. Should be lower as there are no customs in USA for stuff made here, but that requires a lot of paperwork. And my brother is not interested at all in using it, to complicated for him.

For me it is easy, although time consuming, and the fact that mice ate the cabling only pushed me to do the retrofit sooner as i already had all the hardware ready and waiting. This was a fully working machine before the mice incident.
As for step/dir vs analog, i used them both and it is the same for me, i like both.
Mine had some "backwards" resolvers so i had to switch to encoders, i would have liked to keep the resolvers for sure.
VFD was easy, after figuring out what pin/wire does what. The relay board with ... many relays was a pain to follow and test and wire in, but a quickly made magnetic phone holder helped a lot, stick it somewhere-set it to record the DVM-go chase cables around the machine-watch video! Nice physical workout, for sure.
I still have some stuff left to wire in as i need another Mesa 7i84 or i can replace the one in the control panel with a 7i73 as i have one and put the 7i84 from the control panel on the back.
Besides foot pedals, can not recall what else was left out, but the machine is fully functional...with a missing hydraulic chuck!
If you machine is similar to mine, there are a lot of IO there, so i am not sure Pico can handle that but i hope Jon sees this and he can confirm if that is OK.
Mesa also has some boards for resolvers, but first do check what you have to make sure they can work for you.

So, the call to save the tool offset is in the qt_auto_probe_tool.ngc on or around line 202-203 seems to be mangling the tool.tbl format.

203 G10 L1 P#<tool> Z[#<calculated_offset>]

Which occurs after the OKAY click of the tool change prompt. I've checked it before and after.

Thank you Tommylight,
I read that post last night! very interesting build you've done!
Looking back, would it have been worth changing to step/direction digital servos or worth the effort involved with the analogue gear?
Was the VFD hard to integrate into linux with the MESA system? I'm looking at using Pico systems, as they might have a converter for the resolvers.

We need the board type/make as it can not be seen good in the pictures, the green thing with lots of cables.
Also upload here the
TPS.hal
TPS.ini
files so we can have a look at them.

Not sure if this helps, but here is my Mazak:
forum.linuxcnc.org/show-your-stuff/32784...ro-slant-15-retrofit

If you spindle drive can use 5V PWM/DIR control
(and you are not using all 6 step/dir outputs on the 7I52S)
it might be easiest to use firmware that changes one of the 6
step/dir outputs on the 7I52S to PWM/DIR

That would require opening the plasma source and wiring in the torch on, voltage, and optionally arc ok signals.
That is also very dangerous and requires some electrical experience, do you have anyone to help with that?

retrofitting a mazak vtc-20b and it is going great, i have step and dir to all the servo drives. that is running off a 7i52s in first connecter P4, i have a 7i44 on p2, i would like to run a 7i33ta in the middle for the analog spindle. can i just plug it in or do i need a new firmware for the 5i24-24?
also seem like a lot to use a whole 7i33ta just for the spindle, maybe i could use pwm and dir with the gs2015 spindle drive?

After pressing start in PncConf, uncheck the "show advanced option pages" and continue on.

hello Tommy,

PNCconfig will not continue past the External Controls after error. 

Regards

John