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So, to be more coherent on the control desires....

1: A new UI skinning of (probably) qtdragon, possibly vertical layout. I'll do the layouts, I'll need help turning it into a real working UI.

2: A linuxcnc build with a configuration wizard that includes ethercat and modbus, atc types, and some specific presets for lemontart (and then presets for any other machine people like - maybe presets can be just saved out from peoples manual configurations and shared).

3: Jerk limiting.at minimum on any exact top moves. Secondary is to add it to other motion. Bonus points for integrating all the fancier TP stuff from the tormach 1500.

For the physical control, I'm going to do a printed panel, with waveshare touch display, and a common low cost passively cooled dual nic mini itx board. Just so its easy and standard. "go buy these things, assemble, load linuxcnc onto it and run set up wizard"

What firmware are you using?

sudo mesaflash --device 5i25 --readhmid

Will print the pinout of the currently installed firmware

( assuming you are using the 5abob firmware, DB25 pin 7 is stepgen 2 DIR, not STEP )
 

And we're done. Coordinating to start production tonight. Eep! (goes faster when someone else does all the work... and pays for it. )

What version of LinuxCNC are you using?

Did you install from the ISO?

Did you buy those drivers from stepperonline? (there are clones of the clones)

What GUI are you using (I assume AXIS)?

What does the 6i25 connect to?

Perhaps the problem is whatever is between the 6i25 and the drivers.

The pulse pin carries high frequancy pulses, don't trust a multimeter to reliably measure it, especially when it's set to DC.

Try setting your multimeter to AC, or use an LED+current-limiting resistor to view the pulses.

I've been working on a large format gantry cnc for a few months now and while I have plenty of mechanical design experience and a decent bit of controls, LinuxCNC and this style of hardware is well outside of my (current) comfort zone. I've got my HAL/ini files loading into LinuxCNC without error, and am starting to get the hang of syntax and method for this kind of machine control, but I've got some pretty glaring rookie issues left to sort. 

I can power up the mesa board and actuate my steppers with mechanical switches on the 5v and 0v outputs, so my machine wiring is functional and my driver is not fried or otherwise inoperable. I am using 5v on PU+ for power input and then grounding PU- on my z axis stepgen on pin 7, starting the pin count from 0. I have inverted the pin with setp   hm2_5i25.0.gpio.007.invert_output true in my hal and the pin reads 5V when idle so I think I have everything right up to that point. However, nothing moves when homing or jogging a joint, and when I let the home run I see no activity with a multimeter on the pin. I feel like I am doing something dumb and unless I can find a solution I'll go get some daughter cards for the 6i25. For several reasons none of the standard offering quite fit my needs but I can make some combination work. 

Any advice? I've called into Mesa twice and have been able to make a lot of headway from the info gained there to even get to this point but this is where I am starting to stumble. I feel like I am missing something on timing or tuning obvious in retrospect. Files attached.

My Home Position is at the top of the Unit.

yes, I am using the Tool setter Page for the spindle Zero. However the Manual measurement was only off by 0,39mm (202 vs. 202,39mm).

I was using the Automatic Tool changing but had some issues (putting tools back sometimes stopped before the pocket and I had to restart linuxcnc, them the Tool was duplicated in the rack). For now I am switching by Hand.

linuxcnc@linuxcnc:~$ ethercat -p 0 sdos upload 0x1600 0
'sdos' takes no arguments!

ethercat sdos [OPTIONS]

List SDO dictionaries.

SDO dictionary information is displayed in two layers,
which are indented accordingly:

1) SDOs - Hexadecimal SDO index and the name. Example:

SDO 0x1018, "Identity object"

2) SDO entries - SDO index and SDO entry subindex (both
hexadecimal) followed by the access rights (see
below), the data type, the length in bit, and the
description. Example:

0x1018:01, rwrwrw, uint32, 32 bit, "Vendor id"

The access rights are specified for the AL states PREOP,
SAFEOP and OP. An 'r' means, that the entry is readable
in the corresponding state, an 'w' means writable,
respectively. If a right is not granted, a dash '-' is
shown.

If the --quiet option is given, only the SDOs are output.

Command-specific options:
--alias -a <alias>
--position -p <pos> Slave selection. See the help of
the 'slaves' command.
--quiet -q Only output SDOs (without the
SDO entries).

Numerical values can be specified either with decimal (no
prefix), octal (prefix '0') or hexadecimal (prefix '0x') base.

[17147.638691] EtherCAT 0: Released.
[17147.638692] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[17147.638697] EtherCAT DEBUG: 00 00 00 00 
[17147.638699] EtherCAT ERROR 0-0: Failed to receive AL state datagram: Datagram initialized.
[17147.638702] EtherCAT DEBUG 0: Datagram 000000007305a9ff already queued (skipping).
[17147.653272] EtherCAT DEBUG 0-0: Changing state from PREOP to PREOP (forced).
[17147.653276] EtherCAT DEBUG 0-0: Configuring...
[17147.653587] EtherCAT DEBUG 0-0: Now in INIT.
[17147.653587] EtherCAT DEBUG 0-0: Clearing FMMU configurations...
[17147.653831] EtherCAT DEBUG 0-0: Clearing sync manager configurations...
[17147.654076] EtherCAT DEBUG 0-0: Clearing DC assignment...
[17147.654320] EtherCAT DEBUG 0-0: Configuring mailbox sync managers...
[17147.654321] EtherCAT DEBUG 0-0: SM0: Addr 0x1000, Size 1024, Ctrl 0x26, En 1
[17147.654323] EtherCAT DEBUG 0-0: SM1: Addr 0x1400, Size 1024, Ctrl 0x22, En 1
[17147.654565] EtherCAT DEBUG 0-0: Assigning SII access to PDI.
[17147.655300] EtherCAT DEBUG 0-0: Now in PREOP.
[17147.655301] EtherCAT DEBUG 0-0: Assigning SII access back to EtherCAT.
[17147.655559] EtherCAT DEBUG 0-0: Finished configuration.
[17147.673277] EtherCAT WARNING: Datagram 000000007305a9ff (master-fsm) was SKIPPED 1 time.
[17149.457536] EtherCAT DEBUG 0: IDLE -> ORPHANED.
[17149.457539] EtherCAT DEBUG 0: Stopping master thread.
[17149.457556] EtherCAT DEBUG 0: Master IDLE thread exiting...
[17149.457620] EtherCAT 0: Master thread exited.
[17149.457733] EtherCAT 0: Releasing main device 00:0B:AB:B6:75:75.
[17149.477426] ec_generic: Unloading.
[17149.532305] EtherCAT: Master module cleaned up.
[17150.618596] EtherCAT: Master driver 1.6.8 1.6.8
[17150.618712] EtherCAT: 1 master waiting for devices.
[17150.623226] ec_generic: EtherCAT master generic Ethernet device module 1.6.8 1.6.8
[17150.623234] EtherCAT: Accepting 00:0B:AB:B6:75:75 as main device for master 0.
[17150.623242] ec_generic: Binding socket to interface 2 (enp2s0).
[17150.641322] EtherCAT 0: Starting EtherCAT-IDLE thread.
[17150.641454] EtherCAT 0: Link state of ecm0 changed to UP.
[17150.653291] EtherCAT 0: 1 slave(s) responding on main device. Re-scanning on next possibility.
[17150.653294] EtherCAT 0: Slave states on main device: PREOP.
[17150.653295] EtherCAT 0: Re-scanning now.
[17150.653617] EtherCAT 0: Scanning bus.
[17150.834164] EtherCAT 0: Bus scanning completed in 180 ms.
[17150.834168] EtherCAT 0: Using slave 0 as DC reference clock.
[17161.960782] EtherCAT 0: Master debug level set to 1.
[17164.670125] EtherCAT: Requesting master 0...
[17164.670128] EtherCAT DEBUG 0: IDLE -> OPERATION.
[17164.670129] EtherCAT: Successfully requested master 0.
[17164.670131] EtherCAT DEBUG 0: ecrt_master_create_domain(master = 0x0000000069b184e5)
[17164.670133] EtherCAT DEBUG 0: Created domain 0.
[17164.670134] EtherCAT DEBUG 0: ecrt_master_slave_config(master = 0x0000000069b184e5, alias = 0, position = 1, vendor_id = 0x0800005a, product_code = 0x000022db)
[17164.670136] EtherCAT DEBUG 0: Creating slave configuration for 0:1, 0x0800005A/0x000022DB.
[17164.670139] EtherCAT DEBUG 0 0:1: Failed to find slave for configuration.
[17164.670175] EtherCAT DEBUG 0 0:1: ecrt_slave_config_dc(sc = 0x000000008a2cea03, assign_activate = 0x0300, sync0_cycle = 1000000, sync0_shift = 0, sync1_cycle = 0, sync1_shift = 0
[17164.670179] EtherCAT DEBUG 0 0:1: ecrt_slave_config_sync_manager(sc = 0x000000008a2cea03, sync_index = 2, dir = 1, watchdog_mode = 0)
[17164.670182] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_assign_clear(sc = 0x000000008a2cea03, sync_index = 2)
[17164.670184] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_assign_add(sc = 0x000000008a2cea03, sync_index = 2, pdo_index = 0x1600)
[17164.670186] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_mapping_clear(sc = 0x000000008a2cea03, pdo_index = 0x1600)
[17164.670188] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_mapping_add(sc = 0x000000008a2cea03, pdo_index = 0x1600, entry_index = 0x6040, entry_subindex = 0x00, entry_bit_length = 16)
[17164.670191] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_mapping_add(sc = 0x000000008a2cea03, pdo_index = 0x1600, entry_index = 0x6060, entry_subindex = 0x00, entry_bit_length = 8)
[17164.670193] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_mapping_add(sc = 0x000000008a2cea03, pdo_index = 0x1600, entry_index = 0x607A, entry_subindex = 0x00, entry_bit_length = 32)
[17164.670195] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_mapping_add(sc = 0x000000008a2cea03, pdo_index = 0x1600, entry_index = 0x60FF, entry_subindex = 0x00, entry_bit_length = 32)
[17164.670197] EtherCAT DEBUG 0 0:1: ecrt_slave_config_sync_manager(sc = 0x000000008a2cea03, sync_index = 3, dir = 2, watchdog_mode = 0)
[17164.670199] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_assign_clear(sc = 0x000000008a2cea03, sync_index = 3)
[17164.670200] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_assign_add(sc = 0x000000008a2cea03, sync_index = 3, pdo_index = 0x1A00)
[17164.670202] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_mapping_clear(sc = 0x000000008a2cea03, pdo_index = 0x1A00)
[17164.670204] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_mapping_add(sc = 0x000000008a2cea03, pdo_index = 0x1A00, entry_index = 0x6041, entry_subindex = 0x00, entry_bit_length = 16)
[17164.670206] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_mapping_add(sc = 0x000000008a2cea03, pdo_index = 0x1A00, entry_index = 0x6061, entry_subindex = 0x00, entry_bit_length = 8)
[17164.670208] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_mapping_add(sc = 0x000000008a2cea03, pdo_index = 0x1A00, entry_index = 0x6064, entry_subindex = 0x00, entry_bit_length = 32)
[17164.670210] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_mapping_add(sc = 0x000000008a2cea03, pdo_index = 0x1A00, entry_index = 0x606C, entry_subindex = 0x00, entry_bit_length = 32)
[17164.670211] EtherCAT DEBUG 0 0:1: ecrt_slave_config_pdo_mapping_add(sc = 0x000000008a2cea03, pdo_index = 0x1A00, entry_index = 0x6077, entry_subindex = 0x00, entry_bit_length = 16)
[17164.670235] EtherCAT DEBUG 0: ecrt_master_slave_config(master = 0x0000000069b184e5, alias = 0, position = 1, vendor_id = 0x0800005a, product_code = 0x000022db)
[17164.670238] EtherCAT DEBUG 0 0:1: ecrt_slave_config_reg_pdo_entry(sc = 0x000000008a2cea03, index = 0x6040, subindex = 0x00, domain = 0x00000000e562637d, bit_position = 0x00000000935bf368)
[17164.670240] EtherCAT DEBUG 0: Domain 0: Added 11 bytes, total 11.
[17164.670242] EtherCAT DEBUG 0: ecrt_master_slave_config(master = 0x0000000069b184e5, alias = 0, position = 1, vendor_id = 0x0800005a, product_code = 0x000022db)
[17164.670244] EtherCAT DEBUG 0 0:1: ecrt_slave_config_reg_pdo_entry(sc = 0x000000008a2cea03, index = 0x6060, subindex = 0x00, domain = 0x00000000e562637d, bit_position = 0x00000000ac012020)
[17164.670246] EtherCAT DEBUG 0: ecrt_master_slave_config(master = 0x0000000069b184e5, alias = 0, position = 1, vendor_id = 0x0800005a, product_code = 0x000022db)
[17164.670247] EtherCAT DEBUG 0 0:1: ecrt_slave_config_reg_pdo_entry(sc = 0x000000008a2cea03, index = 0x607A, subindex = 0x00, domain = 0x00000000e562637d, bit_position = 0x000000001f67561c)
[17164.670249] EtherCAT DEBUG 0: ecrt_master_slave_config(master = 0x0000000069b184e5, alias = 0, position = 1, vendor_id = 0x0800005a, product_code = 0x000022db)
[17164.670251] EtherCAT DEBUG 0 0:1: ecrt_slave_config_reg_pdo_entry(sc = 0x000000008a2cea03, index = 0x60FF, subindex = 0x00, domain = 0x00000000e562637d, bit_position = 0x00000000adab25ff)
[17164.670253] EtherCAT DEBUG 0: ecrt_master_slave_config(master = 0x0000000069b184e5, alias = 0, position = 1, vendor_id = 0x0800005a, product_code = 0x000022db)
[17164.670255] EtherCAT DEBUG 0 0:1: ecrt_slave_config_reg_pdo_entry(sc = 0x000000008a2cea03, index = 0x6041, subindex = 0x00, domain = 0x00000000e562637d, bit_position = 0x00000000ca53a04f)
[17164.670256] EtherCAT DEBUG 0: Domain 0: Added 13 bytes, total 24.
[17164.670258] EtherCAT DEBUG 0: ecrt_master_slave_config(master = 0x0000000069b184e5, alias = 0, position = 1, vendor_id = 0x0800005a, product_code = 0x000022db)
[17164.670259] EtherCAT DEBUG 0 0:1: ecrt_slave_config_reg_pdo_entry(sc = 0x000000008a2cea03, index = 0x6061, subindex = 0x00, domain = 0x00000000e562637d, bit_position = 0x00000000a5c96db3)
[17164.670261] EtherCAT DEBUG 0: ecrt_master_slave_config(master = 0x0000000069b184e5, alias = 0, position = 1, vendor_id = 0x0800005a, product_code = 0x000022db)
[17164.670263] EtherCAT DEBUG 0 0:1: ecrt_slave_config_reg_pdo_entry(sc = 0x000000008a2cea03, index = 0x6064, subindex = 0x00, domain = 0x00000000e562637d, bit_position = 0x0000000065407bda)
[17164.670265] EtherCAT DEBUG 0: ecrt_master_slave_config(master = 0x0000000069b184e5, alias = 0, position = 1, vendor_id = 0x0800005a, product_code = 0x000022db)
[17164.670267] EtherCAT DEBUG 0 0:1: ecrt_slave_config_reg_pdo_entry(sc = 0x000000008a2cea03, index = 0x606C, subindex = 0x00, domain = 0x00000000e562637d, bit_position = 0x0000000094304504)
[17164.670269] EtherCAT DEBUG 0: ecrt_master_slave_config(master = 0x0000000069b184e5, alias = 0, position = 1, vendor_id = 0x0800005a, product_code = 0x000022db)
[17164.670270] EtherCAT DEBUG 0 0:1: ecrt_slave_config_reg_pdo_entry(sc = 0x000000008a2cea03, index = 0x6077, subindex = 0x00, domain = 0x00000000e562637d, bit_position = 0x00000000ca6b8c7f)
[17164.670281] EtherCAT DEBUG 0: ecrt_domain_external_memory(domain = 0x00000000e562637d, mem = 0x0000000053c8073c)
[17164.670282] EtherCAT DEBUG 0: ecrt_master_callbacks(master = 0x0000000069b184e5, send_cb = 0x000000000166930d, receive_cb = 0x00000000a879b1f0, cb_data = 0x0000000069b184e5)
[17164.670284] EtherCAT DEBUG 0: ecrt_master_activate(master = 0x0000000069b184e5)
[17164.670286] EtherCAT DEBUG 0: Adding datagram pair with expected WC 3.
[17164.670286] EtherCAT 0: Domain0: Logical address 0x00000000, 24 byte, expected working counter 3.
[17164.670288] EtherCAT 0:   Datagram domain0-0-main: Logical offset 0x00000000, 24 byte, type LRW.
[17164.670289] EtherCAT DEBUG 0: Stopping master thread.
[17164.670294] EtherCAT DEBUG 0: Master IDLE thread exiting...
[17164.670301] EtherCAT 0: Master thread exited.
[17164.670303] EtherCAT DEBUG 0: FSM datagram is 0000000086147210.
[17164.670303] EtherCAT 0: Starting EtherCAT-OP thread.
[17164.670332] EtherCAT DEBUG 0: Operation thread running with fsm interval = 4000 us, max data size=45000
[17164.670336] EtherCAT DEBUG 0: mmap()
[17164.670339] EtherCAT DEBUG 0: Vma fault, offset = 0, page = 000000002a6bf26c
[17164.709084] EtherCAT DEBUG 0: Configuration changed (aborting state check).
[17164.709087] EtherCAT DEBUG 0-0: Checking system time offset.
[17164.717079] EtherCAT DEBUG 0-0: DC 32 bit system time offset calculation: system_time=1033070246 (corrected with 8000000), app_time=816644270944702775, diff=-988527
[17164.717083] EtherCAT DEBUG 0-0: Not touching time offset.
[17164.725117] EtherCAT DEBUG 0: Requesting OP...
[17164.725120] EtherCAT DEBUG 0: After requesting OP, rescan_required is 0.
[17164.741097] EtherCAT DEBUG 0-0: Changing state from PREOP to OP.
[17164.741102] EtherCAT DEBUG 0-0: Configuring...
[17164.743878] EtherCAT DEBUG 0-0: Now in INIT.
[17164.743880] EtherCAT DEBUG 0-0: Clearing FMMU configurations...
[17164.744877] EtherCAT DEBUG 0-0: Clearing sync manager configurations...
[17164.745877] EtherCAT DEBUG 0-0: Clearing DC assignment...
[17164.746877] EtherCAT DEBUG 0-0: Configuring mailbox sync managers...
[17164.746878] EtherCAT DEBUG 0-0: SM0: Addr 0x1000, Size 1024, Ctrl 0x26, En 1
[17164.746880] EtherCAT DEBUG 0-0: SM1: Addr 0x1400, Size 1024, Ctrl 0x22, En 1
[17164.747878] EtherCAT DEBUG 0-0: Assigning SII access to PDI.
[17164.750882] EtherCAT DEBUG 0-0: Now in PREOP.
[17164.750883] EtherCAT DEBUG 0-0: Assigning SII access back to EtherCAT.
[17164.751879] EtherCAT DEBUG 0-0: SM2: Addr 0x1800, Size  22, Ctrl 0x64, En 1
[17164.751881] EtherCAT DEBUG 0-0: SM3: Addr 0x1C00, Size  24, Ctrl 0x20, En 1
[17164.754878] EtherCAT ERROR 0-0: Failed to set SAFEOP state, slave refused state change (PREOP + ERROR).
[17164.755877] EtherCAT ERROR 0-0: AL status message 0x001E: "Invalid input configuration".
[17164.757879] EtherCAT 0-0: Acknowledged state PREOP.
linuxcnc@linuxcnc:~$ 

 

"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,