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Hi Chris,

I upgraded to 2.9.3 and would appreciate a hint how to use a custom iu file.

Kind regards
Carsten

I have now solved the issue. Thanks for the help

I contacted the vendor and they advised me to order a replacement card and send the defective one back for review. They also informed me that all boards were tested before shipping and most defects are user error. Now, I only connected what is shown in the pictures for a quick test and the card was not working from the start.

Can someone confirm if I made any errors connecting it? (Not to prove anything to the vendor but to save me from scrapping another card)

"Its alive"!

I think I've found the correct pins in pncof. But when I select the pin for home z axis and it hits the limit switch. Instead of continuing the homing routine it shuts off the whole system and says j3 hit limit in home state. Is the whole point of the homing routine not that it hits the liit switch and then continues the homing sequence for the other axis (I'm homing x first btw). Do I need to select it as a different function? I thought the home function would surely be the correct one

Background: I have a 3-axis benchtop milling machine (PM-833TV) that I converted to CNC. I upgraded to DMM servo motors about 3-years ago and everything has worked like a charm until the hard drive in my HP 8300 died last week. I misplaced my most recent backup HAL and INI files, so I had to modify an older version. They are attached below. I also upgraded from 2.8 to 2.9 after installing the new hard drive. I am using the ProbeBasic GUI. 

The problem: Approximately every other manual tool change, when the Z-axis retracts the spindle to its max travel, I receive a "joint 1 amplifier fault." This is odd because the Z-axis is joint 2. Joint 1 is the Y-axis, which is not moving. Further, when the DYN4 servo drivers encounter an error their status LED switches to red and the drives have to be power cycled to clear the error. There is no indication of an error on the physical Y-axis drive when I receive the fault on the LinuxCNC GUI. Simply pressing the power button in the GUI allows me to resume control of the mill (but it cancels my current milling operation). Further, this "joint 1 amplifier fault" does not occur during long milling operations the rely heavily on the Y-axis only during manual tool changes. 

Any idea what could be causing this? Please let me know if you require any additional information

In pnconf configuration, how do I know which input number corresponds to the input pins on my 7i96s?

Cant do this anymore bye all wrote:

I'm going to have to disagree with you on the need for pull up or pull down resistors on inputs, especially with switches (unless the switch is switching to either zero or 5v)and rotary encoder that have an open collector output. Without a pullup or pull down resistor the input is going to float, until that input has a definite logic level on it. With high impedance inputs it requires very very little current to switch the input, if the voltage is at the right level. Generally on a chip such as the venerable 74xx245 when the enable inputs are in the disable state the output is considered to be in a "high impedance state" and is unable to "drive" the outputs.
Honestly any input that is connected via a cable needs a pullup or pulldown resistor for the case of a breakage in the signal wire, especially with an MPG, if teh signal wire breaks you want that input at the board end to held at a known level. The last thing you want is for your input to pick up stray noise and start oscillating. The chip wont "know" if it is a legitimate signal or noise and will pass that on to the other side.
That's why sometimes I feel am opto isolator is a bit better in this respect as the current required to drive the LED in normal situations is a little higher than induced noise in the line.

Never in my life have I designed a digital circuit that takes external off board signals with pullup or pulldown resistors, or inputs that get the input from a SPST switch from an on board switch without a pullup or pull down.

Before sending this out to the pcb fab, and out of fear this would have been too good to be true, I've set my function generator to 'noise' and beaten up an input with the oscope trigger set to catch a low level. It did after a few seconds. Be pleased to know your advice was taken, I've added 20K pupps on the inputs

You need some voltage across the switch for operation
generally 5V is too low for reliable operation of mechanical
switches so 12 V or 24V are suggested. The 7I96S isolated
inputs are rated to work with 4V to 36V input voltages.

NO or NC makes no difference except for hal settings

You can try 5V but its not the best.

Thank you so much!
is it recommended to do a new setup by the wizard or can I use my old hal and ini?

Sorry..I am not seeing voltages.. probably in wrong spot..?

I get 55 C
54 C

Open a terminal and type while LinuxCNC is running
sensors
What are the temperatures shown?
Then, reboot and enter the BIOS and check what the voltages are in the "hardware monitor" section.

Thank you! Yep, they're 4590 extrusions, but I'm not sure who makes them. They can be ordered cut to length from 8020.net/45-4590.html though, which is super convenient. And yes, I agree, the flexibility of being able to loosen and move then re-tighten the bolts/t-nuts around is great!

Find some of those doughnut shaped ferrite rings and wind the pup wires twice through it.
Plenty of those on old equipment.