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Whoever has access to the server behind linuxcnc.org/iso, please run:

for f in * ; do md5sum "$f" > "$(echo "$f" | cut -d'.' -f1).md5"; done

This will generate an md5 sum for every file in the directory.

It's so easy, why not?!

That is a looooong list !
Yet no machine dimensions, weight of moving parts, drive train, reduction, materials used, etc...
And just putting it out there, 1KW servo motors for a plasma machine is utter overkill, no matter how big or heavy. The biggest i have seen on old industrial machines were 400W, with reduction two of those could fling a probably 200KG heavy gantry at 18m/m!

This is a mod that allows using a single key to cycle through Program Run, Program Pause, and Program Resume.

I unbound the keys R, P, and S from their original commands and bound only the R key to a routine that handles the cycling.

If you’re willing to test it, please let me know if something doesn’t work correctly and I’ll fix it.

I swapped around the inputs and outputs and that solved the issue. I was able to get all the buttons to function. I spent a while working on getting the gmoccapy jog buttons to move the axis but for some reason the only way I was able to get any of the axis to move outside of homing is to use the halshow to select the axis for jogging. Tried tying the ui pins to the pos and neg axis pins. Also almost done with the pendant with the mpg just need the rotary switches and wiring

This is a mod for incrementally increasing/decreasing Feed, Rapid, and Spindle Overrides.

They behave similarly to the Jog Speed slider.

I unbound the keys `, 1, 2, 3, 4, 5, 6, 7, 8, 9, 0

And bound:

1, 2 to decrease/increase Feed Override

3, 4 to decrease/increase Rapid Override

5, 6 to decrease/increase Spindle Override

Keys `, 7, 8, 9, 0 have no effect.

It follows the INI fine settings.

I have also implemented an exponential response to speed up changes. In principle, it works with any exponent, but so far I’ve had the best results with power = 3.0.

If you want linear behavior, set power = 1.0, and then each key press will change the value by one unit.

If for some reason a slider gets stuck at a certain value, set linear_threshold_rate to a value slightly higher than the stuck position. That will solve the issue.

It’s not as quick as a potentiometer, but it works quite well. If you want it to be even faster, try:

xset r rate 250 40

This doubles the key auto-repeat rate and cuts the delay before auto-repeat starts in half.

Try different delay and rate values. The downside is that if you set them too high, editing text files can feel awkward.

If you’re willing to test it, please let me know if something doesn’t work correctly and I’ll fix it.

By the way, this mod is derived from this post: forum.linuxcnc.org/51-ot-posts/49830-com...ntrol-console#279421

I wrote this up in chat gpt pretty quickly I think it just about covers all of the bases here of the project.

CNC Plasma Table – Electrical & Wiring Requirements

Project: Remote design of electrical system + wiring documentation for LinuxCNC plasma table
Client: TCB Metal Works

1. Project Overview

You will remotely design the complete electrical and control system for a custom CNC plasma cutting table powered by LinuxCNC.

You will create:

Complete wiring diagram set (schematic + physical routing)

Full Bill of Materials (BOM) with real part numbers

Wire gauge, shielding, grounding, and EMI mitigation plan

Bulkhead connector list + panel layout

Mesa board selection + full LinuxCNC I/O map

Integration notes for all components

Testing & commissioning checklist

This is a 100% remote engineering job — no physical inspection of hardware is required.

2. Available Power Sources

Near the machine:

220 VAC available

460 VAC available

No dedicated 110/120 VAC, which must be generated using a control transformer if needed

Engineer must design the incoming power strategy and transformer selection.

3. Motion Hardware
3.1 X & Y Axis – AC Servos (Provided)

3× A6 Series 1000W RS485 AC Servo Motor Kits

3000 rpm

3.18 Nm

17-bit absolute encoder

IP67 motors

Axis layout:

Y axis: 2 servos (dual-drive gantry)

X axis: 1 servo

Notes:

Motor-to-drive cables are already supplied by the manufacturer.

You do not need to design or evaluate those cables.

Engineer must:

Design AC mains wiring to each servo drive

Design control, enable, alarm, and ESTOP signal wiring between drives and Mesa

Include needed fuses, breakers, filters, and terminals

Provide cabinet layout and routing plan

Include proper grounding and shielding recommendations

3.2 Z Axis – Stepper Motor (Needs Driver + Cable)

PV267-D2.8AA stepper motor — Oriental Motor

Stepper driver not provided

Stepper motor cable not provided

Engineer must:

Select a compatible stepper driver suitable for PV267-D2.8AA + LinuxCNC step/dir

Define driver voltage supply requirements

Design:

Step/Dir wiring from Mesa

Motor wiring from driver to Z motor

Required cable shielding, gauge, and insulation

Connector type and strain relief

4. Control Electronics (Mesa + Power)

Engineer must select Mesa hardware capable of supporting:

3× servo axes

1× stepper axis

THC-AD

Ohmic sensing

All limit/floating switches

Plasma start / Arc OK

E-stop & safety I/O

Deliverables:

Recommended Mesa board combination (e.g., 7i76E, 7i96S, 7i85, THCAD, etc.)

Justification for chosen hardware

Complete LinuxCNC I/O mapping

Required DC power supplies (24V / 5V / others)

Proper AC distribution, fuses, breakers, and protection devices

5. Torch Height & Ohmic Sensing
5.1 THC-AD Integration

Engineer must design:

Raw arc voltage wiring from Hypertherm HT2000 to THC-AD

THC-AD signal wiring to Mesa

Required shielding and filtering

Scaling notes for LinuxCNC

5.2 Ohmic Sensing (Planned)

Engineer must:

Recommend a compatible ohmic board

Provide wiring diagram for torch → ohmic board → Mesa

Specify cable type and shielding

Document signal polarity & behavior

6. Hypertherm HT2000 Integration

Engineer must design wiring for:

Required signals

Torch start / trigger

Arc OK

Raw arc voltage (+/–) into THC-AD

Required protection

Isolation (if needed)

Surge suppression

Filtering

EMI protection

Routing rules

Arc voltage wiring must be kept separate from low-voltage control wiring

7. Limit Switches & Floating Head
X Axis

2 limit switches:

X-min

X-max

Y Axis (Dual Gantry Drive)

2 limit switches:

Y-min

Y-max

Engineer must propose a reliable gantry squaring / homing method for the two Y motors.

Z Axis

2 end-of-travel limit switches:

Z-min

Z-max

1 floating-head switch (touch-off)

Engineer must:

Select appropriate switch type (mechanical or prox)

Provide wiring diagrams to Mesa

Specify wire gauge, shielding, and cable routing

Provide LinuxCNC input mapping

Include any debouncing/filtering requirements

8. Wiring, Shielding, & EMI

Engineer must specify:

Wire gauges for:

AC mains

Servo drive feeds

Stepper driver feeds

Stepper motor wiring

Limit/floating/ohmic wires

Plasma signals

DC supply lines

Shielding requirements for:

Step/dir

Limits/floating/ohmic

Arc voltage

THC-AD lines

EMI considerations

Cable separation

Ferrite locations

Filtering recommendations

9. Grounding & Bonding

The engineer must design the grounding/bonding approach.

Important physical detail:

The water table, gantry, and control cabinet are three separate physical assemblies.

The engineer must account for this when designing:

Grounding/bonding layout

EMC/EMI mitigation

Plasma return path considerations

Ohmic sensing grounding

No grounding method (star, bus, single-point, etc.) is mandated — the engineer chooses the correct approach.

10. Control Cabinet & Bulkheads

Engineer must design:

Cabinet Layout

AC distribution, transformers, PSUs

Mesa boards

Servo drives

Stepper driver

Fuses, breakers, contactors

DIN rail layout

Ventilation/fans

Bulkhead Connectors

Used wherever practical for:

Servo cables (using glands or pass-throughs)

Z stepper cable

Limit/floating switches

Ohmic sensing

Plasma start / Arc OK

E-stop / operator controls

Ethernet access

Engineer must specify:

Connector type

Pinout

Panel cutout style

Labeling

11. Documentation Package

Engineer must deliver:

11.1 Wiring Diagram Set

Full schematic

Cabinet wiring

Field wiring

Power distribution

Grounding/bonding

Bulkhead connector pinouts

11.2 BOM

Complete list of:

Mesa hardware

Stepper driver

Transformers / PSUs

Switches

Connectors

Wire/cable

Protection devices

Cabinet hardware

11.3 I/O Map

All LinuxCNC inputs/outputs

Axis definitions

THC/ohmic mappings

E-stop & safety signals

11.4 Commissioning Checklist

Power-up verification

Servo enable/jog

Stepper test

Homing / gantry squaring

Z floating-head test

Plasma start / Arc OK

THC test

Ohmic test

EMI/noise checks

What material is being milled?
You wont like this, but that can very easily be mechanical flex from aluminium parts, there is reason why cast metal is used for mills.
Still, a quick test for that is to make the same part much slower and check if the error is smaller.

About the following error, there is no real position feedback, only position feedback from stepgen.
That P=500 is ok for your 2 ms servo-period?
 

Mwchanical issue maybe or backlash of your acis settings are correct.

Your approved, the move to private was not my doing, FB forced group chats to private chats last month i think.

Thanks for the info. I sent a request to join the probe basic facebook group. It appears to have gone private in a new group that is members only.

Give this a try
forum.linuxcnc.org/9-installing-linuxcnc...an-edition-6?start=0
or if you are OK with 2.10 version dating nearly a year back, try this
forum.linuxcnc.org/9-installing-linuxcnc...-1-linuxcnc-2-10-iso

thank you I decided to take a few days brake on this reinstall.. "note to myself dont touch things that work lol"

Tried first reinstall 2.9.4, that did not help. then i installed "linuxcnc_2.9.3-amd64.hybrid" same problems as before+ expkey signature not valid due to age, but that's ok ish.. . I think there are a "update" being loaded on install or right after that bugs it. .
one thing i don't get also is when i installed 2.9.7 first time it showed Debian 13 with "red theme" ??
...... i think i will put the install on pause for some days because i am going insane lol .. thx for helping

Now added to my mirror.

The offical download site should really have the md5 or at least some checksum for all the files.

The files on my mirror are identical to those on linuxcnc.org/iso though only 2.9.4 (Bookworm), 2.7.14 (Wheezy), and an rPi version are available from my mirror.