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Also, as of now everything is new on the PC. I have an older dell optiplex I can play with if we think thats the issue…

here are my hal and ini files. I only have a few buttons working at the moment so it should be pretty generic so far

OK that sounds more like a hal issue or maybe hardware (Memory?) issues on the PC

Can you post your hal/ini files?

 

  When I say crash, I mean the computer shuts down and reboots.

The 7i77 is powered by an external 5vdc supply. Here are some pictures of the wiring 


I am getting 5vdc between the screw labeled vcc and 0vdc. Interestingly, I can start LinuxCNC with the encoder hooked up and it will not crash unless I move the hand wheel. I used halshow to verify other buttons are working (joystick, start, stop, etc.)

power supply for 7i77 is 15w/2.4 amp

Can you power the 7I77 from an external 5V supply?

When you say crash, what actually happens?


 

OK guys, 
Finally back on this again. Got LinuxCNC stable, ended up being a failing hard drive issue. Got my 6i25 and 7i77 boards back from MESA, everything checked out ok. 
I am still struggling on the MPGs. Still crashes the computer when I scroll the MPG handwheel. Its a differential encoder, plugged into encoder #3 slot on the 7i77. I have tried a new MPG, same result. I would say its safe to say the MPG hardware is not the issue. 

Also make sure all power management is disabled on the host PC
Similar issues can come from Ethernet (EEE) or PCIE power management

I had a problem with a Mesa board disconnecting a couple years ago.

Turned out it was a bad/weak DC-DC power supply.  Voltage would drop intermittently, causing the Mesa to reset and I'd get the 'error finishing read' nightmare.  Looked like a network issue, but @PCW helped me diagnose it as a power problem.

Maybe double-check whatever is powering the Mesa and see if it's dodgy.

Just talking from my experience, on my machine i got good result with ilowpass / multiply stepsize

setting for all axis:
MAX_ACCELERATION = 1100.0

If set Stepsize on mpg to 100 or less, it works very good. Even stepsize 500 worked, larger was not safe.
jog-counts and jog-scale can be set for all axis, only the enabled axis will move finally.
This config was made many years ago, thats all i remember

# The stepsize selected is always multiplied by 0.001
# ilowpass − Low-pass filter with integer inputs and outputs
# mult2 − Product of two inputs
 

The Default Axis?

Which interface for linuxcnc u using?

still interested in taking a tcl touch screen version of axis further any interest?
will like to add pause routine as per 3d printers etc

Ich habe jetzt getestet mit und ohne Erdung des Computers - das Problem trat natürlich nicht auf! Ich versuche es später noch mal, mit laufender Spindel...

I don't know what you mean by "queue error" but here's my situation:
I have a pair of mechanical NC probes, one toolsetter and one touch probe. Both are a bit sensitive to machine vibrations (the machine is aluminum extrusions) so I added debounce to reduce those. The toolsetter still trips when I rip a pocket off, but that's useful
However, because of the debounce, the probe trip is now delayed and unpredictable, so I have to probe very slowly.
The probe operation is:
* probe towards, record hit.  Speed in the 1-2 in/min range
* probe away, record hit.  Average the hits to get the final result
* G0 away to clearance.
The problem happens when the "probe away" is still unstable during the G0 move (there really isn't a "deceleration phase" here).  I suspect it's a symptom of the probe design, as it gets *worse* as I go slower, as if the contacts were scraping past each other (yes, I know it's not that kind of probe).
 

I did a calculation:
with 4 ethercat sto servos, beckhoff ek1100(interface), el1809 (16inputs), el2809(16outputs),el4102(vdf control) im getting ~50€ more expensive than mesa + 4 cables.

If I ditch the beckhoff and handle i/o by the servo drives im more limited in machine control and vfd has to be set manually. Spindle control could be added later when I need more i/o for toolchanger anyways.

Basicly a drive i/o system instead of a centered i/o.

Thats why I have difficult times deciding stuff like that, I have two in my eyes equal options. Sto would only come in when using ethercat tho, so theres that.