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That means if a PC running Linux happens to break, you can just take out the HDD and plug it into another PC and it will work no fuss, no muss.

Yes, for the last 20 odd years Linux could do that, even through external USB cases and/or CD/DVD rom's.
That is very hard to explain to "PC experts" who used windows only as that never worked, till win10 had that haphazardly implemented and intermittently working about 5% of the time.
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Just guessing that the port migration is because USB communications were
lost due to EMI as soon as the VFD started.

Does the VFD have a line filter?

I would keep the USB cable as short as possible and try wiring the RS-485 connection
through a common mode choke (a large ferrite bead)

Also check the VFD frame grounding

VFDs radiate EMI like a radio station, and USB is typically quite poor
in EMI resistance.

 

If the ferror is in the opposite direction of the velocity plot, FF1 is too high (first plot, FF1 = 1.8 is too high)

If the ferror is in the same direction of the velocity plot, FF1 is too low (second plot, FF1 = .027 is too low)

On the polarity, it should be checked with a voltmeter and the most positive lead goes to the OUT+ pin.

Spoke too soon.

After verifying the VFD parameters and the loadusr arguments to insure matches, I was able to issue a M3 S6000. The spindle enable relay activated and the spindle ramped up to 6000. However, M5 did nothing and I had to stop the spindle with the VFD control panel.

Next I tried to rerun the M3 S6000 command. I heard the relay activate, but the VFD did not respond. I shut down and restarted LCNC this time it failed to restart complaining that about not being able to communicate with the VFD. Checking dmesg I found that the dongle had migrated from ttyUSB0 to ttyUSB1? I updated the custom.hal and restarted LCNC without issue. This time I issued a M3 S10000 which worked perfectly. but again M5 was ignored.

I've now gone through this sequence several time and each time the VFD starts at the requested speed, then fails to stop. Each time the dongle migrates to a different ttyUSB1/2 port. The last time I issued a start command I noticed that the pyVCP display did not show the speed nor at speed and as I was monitoring the display I saw the OS notify that the dongle had again reattached at a different port.

At this point I'm confident that I can communicate via hy_vfd to VFD, but I'm frustrated that the dongle keeps toggling between ports on its own. Any ideas what is going on and how to resolve the issue?

How about reflashing the mesa 7i77 firmware?

I started linuxcnc in debug mode and when I enable the machine I get this error:

joint 0 following error
emc/task/taskintf.cc 976: Error on joint 0, command number 226
task: main loop took 0.112439 seconds

 

An alternative approach is to create a custom mux2u32.comp component by adapting the existing mux2.comp—replacing its float data types with u32. Once modified, you can compile it with halcompile and integrate it  into your local LinuxCNC. 

Im finding it quite hard to track down a mini itx or micro atx mobo with intel NIC. they all like to use the realtek it seems.

Maybe i should just get an add on card with intel chips?

I think i saw something on youtube yesterday about Linux desktop passing 5% and since about 3-4 weeks ago it was at 3%, that is huge, and personally, i am not looking forward to it getting over 20 or 30% as so will the malware and other s#it for it, and developers are dropping like flies every day due to burnout and lack of finances and ... being p.o. at microshaft misusing github and Linux code crammed into windows and .... to long list.

Thanks for the quick reply. I've been referencing the servo tuning guides, which have been helpful. Would you go higher or lower on FF1 and how do you best determine if the f-error is at an acceptable level? The drives move smoothly, but unsure how much more tuning is needed.

For the polarity issue, would that be in the wiring, swap terminals at the board?

Well Linux just gets more attractive every day.

 

I guess you didn't watch the presentation or pay close attention.

The driver for the Mesa PCI\PCIe cards are loaded during the startup of Linuxcnc.

Linux has no issues loading kernel modules for supported hardware that are added after installation, if this was not the case live versions of Linux wouldn't work, installers for Linux would fall over.

If you have ever read the output of dmesg you would see very clearly that the kernel detects the installed hardware and loads the kernel modules as required, or the hardware may have support compiled into the kernel. With the caveat that the kernel "knows about the hardware". There is absolutely no need for the hardware to be present during installation. For hardware that is "hot swappable" the hardware is not required to be attached/inserted/present during boot, it is detected when inserted, and no this is not limited to just USB devices.
I'm quite astonished at the amount of information you post that is wrong. This is quite a distressing matter as one day someone will take your advice as true and have a very bad experience. You really need to reassess your level of knowledge and take some time out and sit back and learn.
When you are not being wrong you are not addressing the subject matter and being unhelpful.
As I've suggested before read a book and learn.

Linux loads hardware modules at boot time, no matter if it was plugged in during install or not.
Proprietary modules/drives will nor be loaded during install nor after, they will have to be installed separately, like NVIDIA or AMD ROCM drivers.
Linux is extremely good with this as you can even add hardware while the PC is running, granted that hardware does not require BIOS initialization, and it will happily load required modules, like USB video grabbers, and in some cases SATA and PCI-E stuff like hard drives and NVME if set to "hot plug" in BIOS.
I recall having to reboot the windows PC to be able to use the USB stick you just inserted...ah the trauma!!!

FF1 can be tuned further to flatten the ferror plot

Once this is done, you can usually add some I term

If a SSR seems on all the time, it may be that you have the polarity backwards

Getting back to this project.  Servo enables are working now, and started the drive tuning.  Was wondering if someone could take a look at the attached images and provide any recommendations.  Drives are moving smoothly with the tuning parameters, but wondering if there is further improvement to be made in the servo tuning.  I also have an issue where the torch enable signal is being sent all the time.  I have not fully debugged this yet in the wiring, but any suggestions on if there is a configuration issue that could cause this?  The LED on the SSR on the board does light up when the torch pulse is toggled to on.  

Without FF1/FF2 Tuning:
 

With FF1/FF2 Tuning: