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Forgot to include the picture of the Z-axis so here you go. Also noticed that the y and z axis uses the ball screw mechanism while the x-axis uses rack and pinion mechanism.

Thanks for the advice, Tommy.
After reviewing all the information exchanged so far, do you think it's a good idea to start a new thread about retrofitting our Sbz 130 model?
Basic differences include:
1) all 4 motors are AC 3 Phase, with integrated 2-pole resolvers
2)no short X-axis
3) newer DARC system (drives motors) (manual attached)
4) possibly different mesa configuration (6i24 7i49 for resolves feedback and - 10V of analog control signals for motors?)
5) 2001 model
6) No pneumatic brakes are used for the x and y axis but we did notice some sort of pneumatic counterweight or brake for the z-axis (picture included)
7) In the picture you can see the 'DARC system' comprises of from right to left: supply module, that receives AC 380-415 3ph, then distributes through dc links (metal bars under the grey boxes)  L+ L- PE to the other drives (spindle, x, y,z), diagram attached as well.

Attached is a picture I got online of the control panel with all the connections intact of the same machine 2001 model. The next picture shows the internal connection on the top side of the spindle motor. The next picture shows the cables for the resolvers found in the DARC manual. A picture of the whole machine in its current condition is also attached. A table containing info about the motors used is also attached. A diagram of the DC linkage is also attached that distributes power to all drives sharing and originating from the supply module, all drives also have inbuilt inverters to send 3 ph AC to their respective motors.
This is a link containing the DARC manual and the electrical schematics for the SBZ 130 - we.tl/t-zhbMsN1qWM
 

Sorry, my research says zram is not installed by default on Raspberry OS. I don't see this is a Linuxcnc issue.
We've always said to use a 4 GB system and with that much ram, mamory caching is not required.

Maybe it is time to do some improvements and clean up. Like making PDOs of the scale and max-acceleration.
I wonder how much you have done to the code?
I can bring in those changes in the code, and push an update to github.

I see, a bit like EasyCAT kind but for the voltage reader.
 

I am more into putting the torch voltage reader components onto the EaserCAT board.
Now when I have looked at it I am not so worried about the voltage levels and that.
One just need to take some precautions.
And if I understand right, most new plasma cutters gives out scaled down voltage
so it is more to handle the floating voltage, and this circuitry does that.

Gday, unfortunately I have been snowed under with work and life stuff, all the parts are here now but no time to do anything in the shed. I still need to wire up the shed!

Sure, I'll set a reminder on my phone to post them when I'm at the pc. My files might be a little odd though. I started by using JT's config tool. Then compared the result to a 7i97t sample config to get the spindle working. Some of my "net" pin stuff is in io.hal and others are in the main config.hal

I have received a lot of help from everyone on the forum.

zram issue Sat Feb 22, 2025

Big thanks to forum user spina for finding this.
Tho not a game stopper, doesn't seem to affect the operation. Just entries into /var/log/boot.log
Is related to swap.
So far no reports of adverse behavior has been reported.

A reboot can be done now or you can edit the file mentioned below to prior to rebooting.

By default up to 4GB of ram or half the ram is used, depending on how much ram one has.

On my 4GB system I have the following entry, which allocates 1GB to zram swap......the file to edit is after the # symbol.
Apologies for missing this prior to releasing the images.

No motion or PWM is possible because LinuxCNC is not in a machine-on state:

30 bit IN FALSE hm2_7i97.0.pwmgen.00.enable <== joint-0-enable

Also the ferror limit is still 0.001:

23 float OUT 0.001 joint.0.f-error-lim

You cannot start tuning without increasing the min-ferror and
ferror limits(for all joints) or you will get an immediate ferror and
not know the cause.