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hakan is on the right track
There are a couple of xml files here with configs for Rtelligent and Deiwu I.O modules created exactly how endian menrions
github.com/rodw-au/linuxcnc-cia402

 If you get a USB wifi dongle with an external antenna you can get a SMA extension cable with a bulkhead connector on the end. Drill hole through enclosure, insert fitting and attach with supplied nut, and attach the antenna from the dongle. I have done this a few times now.

small update moving forward with this.

Found another problem that seems to have fixed it. The machine is manufactured in the east, the input switches/buttons go through a wide metal clamp that I assumed was frame grounding the shielding of the wire, it was not. When I earth grounded the shield with the setp suggestion the random EStop trip seems to have stopped. It will take more tests to be sure.

Input common is Negative on the 24v PS. Limit switches are inductive and signal 24v when tripped, EStop will be 24V normal, 0V when triggered.

Yes, limits triggering will also cause a fault and change to machine-off state.
Maybe a wiring issue with the input common, or just limits/estop wired
near power signals.
 

ok there is a freight train at the end of the tunnel!
It worked sort of. Not stable but it did show what is happening.
I put the setp on all inputs.
The EStop I now see toggles which it should not. The EStop is not actually wired yet and will be normally closed so there is always a 24V. Would this stop noise? The limits send 24V when detected but the spindle is not running. Will a limit triggering while operating cause any issue?

No need for a base thread with an external motion controller.
I run mine with a NVMe drive, yeah boot is really fast, I've been playing a around with custom hardware and hostmot2 firmware over SPI. ATM I'm working on a ethernet board to replace the SPI\EPP board that mates with the fpga board I'm using.

If you could add your Etherent mods to the thread linked below it would be great, trying to have a one stop place for all issues/suggestions and such.
forum.linuxcnc.org/9-installing-linuxcnc...official-images-only

Cheers
Rob

I think the raspberry pie five and Mesa set up is really quite brilliant. It’s very compact, and boots up really fast. The only negative i have found is that it’s difficult to put an external Wi-Fi antenna on the pie. If the pie is inside a metal box, it won’t connect easily to a Wi-Fi router. You can get around this by using an external Wi-Fi dongle. Or move the excess point and pie closer together.

The reason I was running that test was because packets were being lost between the raspberry pie and the Mesa board. I couldn’t figure out why. It was suggested to change a setting (I forget which one, but it is documented on The Forum) and after that there was zero packet loss.

Yes. I don't always trust over seas items so even if they don't have a ground lug they are grounded. All wire has grounded drains, 7i96s frame ground, emi filter, spindle, machine frame, stepper drivers are all grounded to earth ground

Looking at the hal file, I would suspect the estop input so you might try adding:

setp hm2_7i96s.0.inm.00.input-06-slow true

(the noise may also affect the other inputs so you might try with all)
 

Does the machine and PC have proper grounding?

Here are the files, axis are not tuned only tested for basic motion.
I added Ferrite cores to the UVW of the spindle, checked all wires are grounded properly. They are all foil wrapped with drain. All drains are grounded. I even moved the EMI filter and VFD to as far away as I could (6 feet) without having to completely rewire. Same issue if I turn off the VFD breaker the M3 command holds with no reset, with the breaker on it resets in a second or 2. I removed the xboxctrl.hal but included it here. 
Thanks for all your assistance.

pgf wrote:

Secondary question: I don't have a Z+ limit switch. My mill is so slow I'd really have to not be paying attention for the carriage to get close to the stepper. A lower limit would be nice, but I really don't understand how that could work. My spindle is a router, so the bit length varies a lot. Is there any way to configure this to work? I see people say that they don't bother with a lower Z limit, and just rely on a soft limit there, but what would you set it to? Is there something about "real" spindles that I don't know? Are the bits always the same length?

No need for lower limit switch, LinuxCNC is very good at obeying soft limits, and you set it to the actual hardware limit, so if say Z is able to move 200mm it is set at -200mm in the ini file as the min_limit.
Upper limit switch is nice to have as it is also used as the home switch in LinuxCNC, so the top of the Z becomes 0 in G53 coordinates, then you put the tool in, jog till the tip of the tool touches the surface of the material and you do a touch off in G54, jog up a bit to avoid hitting something and press run.
All the usual CAM software outputs gcode where 0 it the top of the material and everything below it is negative values, hence the above -200 example.
As for tools, no they are not the same length, and above is how to deal with them.
The thing with hardware limits is, no matter what G54 is set to, LinuxCNC will not allow the machine to move beyond what limits are set in G53.
And then there is G55...

I didn't try it, but I have a good experience with Gemini 2.5 pro to configure (text based) a midi controller with custom firmware just by uploading the manual and explain what I wanted. You could try the same with LinuxCNC, upload the right PDF and tell that this is the manual and explain what you want. If it doesn't give a good result try without the manual but add the right prompts.
In the PDF you can see the result with adding the manual, I didn't look at it throughout but it seems already make more sense. (If you indeed will use remora)