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Here's a pic!

So as far as I can tell there is a few ways to zero out a c axis that can be disengaged. 
1, engage the axis drive then drive the spindle around till the spindle reaches its encoders 'z' point.
2, engage the axis drive then re-zero the c axis (it has a prox) then reading both the spindle position and the current position adjust the c axis position. - the c axis position could be set on startup. 
3, stuff around and get spindle alignment working (m19) - this is no easy task using modbus for spindle drive.  Then drive both to a point where the gears mesh.

What are some solutions people out there have used?

If you post your hal and ini files, I can take a look.

Thanks
I think I know where I have gone wrong.

I was working of a chinese translation of the above and thought the driver was suppling its own power. Now ive read the english one above better i need to supply 24v power in to pin 11 and earth pin 9 to make it work.
Will try when i get home and hopefully get some action.

The 7I97 input will work with either input polarity
You should not be able to damage the THC output
as long as you do not wire it directly to power.

The 7I97 input will only put a ~4 ma load on a 24V signal
so as long as the wiring includes the 7I97 input pin pair
in series, there should be no way to damage the THCs
optocoupler outputs.
 

I just tried what I think is the top right example without any impact.
I put a jumper between pin 17(thc)and pin 25(thc field +12v) on the thc connection.
then I ran pin 4 (thc) to tb4 pin12(7i97t).
and pin 20(thc field common) to tb4 pin 11.

Is there an easy trick to get arc ok signals without having the arc going?
It was hooked up to a hypertherm hsd 130, but I hooked up a thermal dynamics a60 just to make sure the plasma was actually sending the signal.

Rod,
If I don’t get this figured out soon, I may pick up the z axis you recommended in the other thread. Do you have a link?
Also thanks for sending the corner hold, I haven’t had a chance to look at it, but I appreciate it. 

Im broke and over budget so I’d like to get what I have working, but who knows if that’ll happen.

Alternatively, maybe I can just reuse the z axis I have with a thcad and something like a mesa 7i30 since the z motor is an h bridge. But I’m not even sure what an h bridge is.
This thing is turning into a can of worms.
 

I was running a 2.9.0 prerelease and decided to upgrade to the current 2.9.3. That seemed to go smoothly, but now when I launch linuxcnc, it exits with the following. Looking at the apt upgrade transcript, it definitely installed some GTK stuff. But this is the main error:



I've struggled a lot in the past with GTK 2 vs 3 issues. I'd be happy to move to GTK 3, if Axis and LinuxCNC can handle that, but I'm not sure how it would break my VCP. I've attached some files in case they help

From their diagram it looks like the output is switching on the negative side.
If the 7i97 is expecting a positive input, this will not work. I don't know the card but I am sure PCW will guide you.
A relay may be required to send +24v to the input. example bottom right.

I've never noticed this before, but today every time I quit LinuxCNC, I'd get this written to the console. Any idea what's causing it? Doesn't matter if I click the X in the window title bar or choose File->Quit.

Version: 2.9.0~pre1+git20230208.f1270d6ed7

I hesitate to even ask about anything that’s not a mesa thcad, but I’m going to anyway.
Im trying to get an arc ok signal from a hypertherm thc to a mesa 7i97t.
The thc uses a 25 pin d connector. Arc ok(motion according to the thc manual) uses pin 17 + and pin 4 -.
I originally connected pin17+ to my power supply common and pin4- to tb4 pin4 on the 7197t. Tb4 pin6 is connected to v24+ on the power supply. 
After a lot of unsuccessful testing, I realized I mixed up my positive and negative.
So I swapped pin17 and pin4, but that didn’t help.
I also tried throwing a relay in, but that didn’t help either.
Now I’m wondering if it’s possible I damaged something with my incorrect wiring.
I know you guys probably aren’t familiar with the thc, so I attached what I think is the relevant part of the manual.
It a hypertherm sensor phc. I’m planning on hitting up hypertherm tomorrow to see what they say.
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I've been working on this subroutine to surface my router table spoilboard (attached). It's a loop that starts at the current origin and works its way up and down Y, stepping over along X by a fraction of the tool width.

The Y moves are relative. The X moves are absolute and controlled by the loop variable. It worked once without issue. I ran it again, and it stopped after a few passes saying the move would exceed (or exceeded?) the machine's negative Y soft limit. How is this possible? 

No that doesn't help at all. The problem is that every time I relaunch linuxcnc I have to rehome the machine. That can take ages if I'm working on the opposite corner.

Not that i know but if you start linuxcnc from the command line the commandopens the last config.
Hitting the up arrow in the console brings up the last command you typed
So it becomes very quick to rerun the last config when making changes etc.
 

At a guess, the image you have used is 32 bit and the Pi4b is 64 bit
Please use the image on the linuxcnc downloads page and not the comments arouns seting wifi etc.
 

Ah. It happens when you end your while loop with "end while' and not "endwhile"