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Found the solution by motivating tommylight to take a detailed look at it , spent him some hours of his night life Jokes away he is a master.
Thank you Tommy

Oh good, someone else replied about the RPI, i was going to go postal!
For 35$ it is magnificent, even 50$ is OK mostly, not a single cent more.
For 100-120$ i can get old Lenovo X1 Yoga, full PC with touchscreen, battery, and much more powerful than RPI.
Also:
PC: download ISO, install ISO, reboot, copy config, run machine!
RPI: download IMG, no not that one the other one for V5 with 4GB not with 8GB or 2GB, write image, boot.... for a while, nothing works, fix wifi, fix power options, fix servo period, use raspiconfig, edit config.txt, fix whatever Unknown mentioned, reboot 20 times, find another power supply, find a cooler to glue to it, find a faster SD card, it crashed ... boot loop, start over. Oh hell no, never again.

As always, great starting points. I'm waiting for my EL2502, although the EL2521 seems to work just fine. Thanks, Corbett and Rodw.

The way I understand it, when I command a rapid move, the Mesacard wants to give it the full 10V, leading to a really rapid move on the motor, way to fast for what linuxcnc anticipated, and that will cause some issues.

 
That's not actually what happens. With velocity mode servos, tuning LinuxCNCs PID FF1 term is what mainly
determines the output voltage correspondence to requested velocity. If FF1 is tuned properly, the analog
output voltage will generate very close to the correct velocity in the drives. Any small per cycle or
cumulative errors are corrected by the P term position feedback.

One way to get a good initial value for FF1 is to set the analog scaling so it is equal to machine units per second
at 10V. In this case FF1==1.000

 

Yeah! Just as soon as I can figure out just what I'm missing to get a piece of gcode to run after loading, sure. Once I open a .ngc file (says it doesn't know what an .nc file is?????), nothing I do will allow me to click cycle start. The cycle start button is never active.

I have more than a few questions and the most of them I don't even know what to ask. Never the less, I keep hacking away.

There is a thread with a guy integrating a cm carrier board with a 7c81.
The RPi5 works but it's a very expensive option compared to an ex corporate PC. The only real advantage is size and that's about it. The RPi5 images work out of the box, but do require the zram fix mentioned in the big thread, it's not a game killer but can raise its head.
Having a RPi5 and 3rd Gen I5 running for testbeds the i5 is definitely the one I'd choose for a build.
For my mill I running a odroid H3 and can not fault it, this has been replaced by the H4.
As for pre-built control boxes, any that rely on the parallel port can be used with a 7i92 for an ethernet option or a 7c81 for SPI with a Raspberry Pi. Some of the issues I have with them is use of DB9 connectors for the Stepper motor connectors. Most of them are quite compact which raises issues of heat and airflow.
I prefer to build my own, lots of room for air flow, the ability to keep the mains and signal wiring well seperated, on side has all the mains, the other side has the low voltage signalling.
I guess if that isn't part of your skill set then an off the shelf control box might be the option if you have the funds.

I updated everything again and created a new configuration. 
Now the spindle zero value is saved in the var file, but in Probe Basic, after closing and reopening it, it shows the value 0, but the value I entered remains in the var file. 

If I enter a value of 227.0000mm, for example, the value always remains in both the var file and the interface. However, if I enter 227.5456, it is saved in the var file, but then it appears as 0 in the interface.

Welp, homing switches were 100% inverted.

Homing now works on Z and Y, I have a wiring/driver/stepper issue to diagnose on X.

Thanks for that, I will review the documentation and try implementation later today.

John

Maybe i was not detailed enough, all configs have search and latch velocity positive for both, OR negative for both, plenty of those configs, only one has one joint where those two values are not the same direction.
To be more helpful, use Rod's advice and slow down everything to a crawl so you can actually see what is going on.
Before that, do absolutely make sure the motor direction is correct.

Actually, the sign does matter because I have had machines where one side of the gantry does not home until the sign is flipped!

Thank you for your answer! I like to dream big sometimes Of course having this for sale as a bundle would be epic, but even if I just managed to make a github repo with the whole config + BOM + CAD model of the control cabinet, I think that'd still be really helpful, right? Also, is Raspberry Pi really so bad for this goal? What are the disadvantages? I thought it's a pretty nice option given that it's quite compact and rugged.

Yes iv A and B hooked up to the PV which is working, counting fwd and back. Iv another encoder that came with the machine stock (emco encoder) that I'm using for the Z as it's 24v and hooked straight to an input pin. Yes iv the spindle speed in , in my Hal file same as yours.

i fixed everything so it all good information now.

tommylight wrote:

Just checked some 15 of my old and new configs, luckily i found one where search is positive and latch is negative (on Z), all others are same direction.

I checked another config of mine and it was positive.
github.com/rodw-au/showstopper/blob/master/my_Plasma.ini#L260

I wonder if the sign matters? I don't have the machine anymore to check.