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"Invalid output configuration" means SM2 isn't configured correct. You ethercat-conf.xml now looks fine.
It can be that you may need to configure sm2 yourself using initcmds.
Let's investigate a bit first. Enable ethercat debug with "ethercat debug 1", try to start linuxcnc
and show the contents of syslog from that start attempt. There should now be more output in there.

Secondly, investigate what's in SM2.
Show the output of... as many as the output of the first command says. It should say 4 I guess.
This output should match what you have in ethercat-conf.xml Index subIndx and length in 2+1+1 bytes,
like 0x60400010 for index 1. If one find that this mapping is wrong, one can download the wanted mapping.
And -p 0, the zero is the slave number of your servo.

nvlpubs.nist.gov/nistpubs/Legacy/IR/nistir5331.pdf
nvlpubs.nist.gov/nistpubs/Legacy/IR/nistir5307.pdf

Does it include an NDA?

Hello. I am looking for a free lancer who would be interested in drawing schematics for a cnc plasma table i am building and assisting in choosing the correct parts etc. My goals for the table is for it to be reliable against tough environments and have strength against interference. If someone is interested I can get them up to speed on the project. If someone is interested please reply here and we can exchange information. 

  I actually mixed up the files earlier. Here is the proper configuration file I'm using now.

Looks good so far. Those Unmatched might have been an EoE effect.

How come you put in those idx="0000" pdos in the ethercat-conf.xml?
I have never seen such before and that can't be right?
I would remove all those pdo idx="0000"

 

This is likely to cause rounding errors when the number of encoder counts per pocket position is not an integer. You might need to convert the pin to "float" so that it can take a value of 682.6666666666666 (which means that the rounding error won't be noticed for several million full rotations of the carousel)
Luckily "carousel" is just an ordinary ".comp" file and so it can be re-installed after editing with halcompile.

If you get a "command not found" error then you may need to sudo apt get install linuxcnc-uspace-dev,

I think that carousel.scale needs to be 8192/12 = 682.666666666 (which is unfortunate, as there is a possibility of rounding errors.

The "width" is how many counts you can be away from the target and still consider the carousel to be aligned. On reflection I might have been able to think of a better name for it. But it corresponds to the "width" of the typical flag or proximity sensor used to detect carousel alignment.

Carousel can be configured in many different ways, and some setups simply don't require certain inputs and outputs.

The latency looks OK now, 20k is very usable.

You might want to switch your Z axis round, so 0 is at the top and -300 at the bottom. Some CAM packages assume that G53 G0 Z0 is a safe retract.

Thanks for saying what the problem was, I will try to file that one away in my mental list of causes of tool change errors.

Thanks.

The circuit diagram is OK?

I'm using Output 5 for Spindle ON and a contactor with the emergency stop button circuit.

Windows NT is briefly mentioned here:
en.wikipedia.org/wiki/LinuxCNC

and here
linuxcnc.org/docs/html/common/emc-history.html

Thank you, the comments in the source code are much less detailed than in man (this is strange). It would be right to bring the man to the proper level. Thanks again. When I install 2.9.x I will publish detailed startup instructions.

DOS is also not mentioned in that document.