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Hello Spumco, no worries, I just wanted to know where you were with the C axis.

I launched linuxcnc, "ethercat slaves" are in OP state, everything seems correct in the XML configuration, what could be the problem?

0  0:0  OP  +  2DM880-EC
1  0:1  OP  +  2DM880-EC
2  0:2  OP  +  2DM880-EC
3  0:3  OP  +  2DM556-EC
4  0:4  OP  +  2DM556-EC
5  0:5  OP  +  DIEWU EtherCAT-IO (Digital 16-Input/16-Output)

When running the configuration, such errors occur:

Debug file information:
Note: Using POSIX realtime

HAL: ERROR: duplicate thread name servo-thread
THREADS: ERROR: could not create thread 'servo-thread'
threads: rtapi_app_main: Operation not permitted (-1)
./Sodick.hal:20: waitpid failed /usr/bin/rtapi_app threads
./Sodick.hal:20: /usr/bin/rtapi_app exited without becoming ready
./Sodick.hal:20: insmod for threads failed, returned -1
shutdown.hal:4: parameter or pin 'lcec.0.0.enable' not found
3184
Stopping realtime threads
Unloading hal componentsNote: Using POSIX realtime

I tried to fix the access error:

groups
sodick lp dialout cdrom sudo audio video plugdev users ethercat linuxcnc ecusers realtime

And all lcec files installed from linuxcnc:

/usr/bin/lcec_configgen
/usr/bin/lcec_conf
/usr/lib/linuxcnc/modules/lcec.so
/etc/linuxcnc/lcec.conf
/usr/lib/linuxcnc/modules/lcec.so

Hal file:

# Загрузка EtherCAT компонента
loadusr -W lcec_conf /home/sodick/linuxcnc/configs/Sodick/ethercat-conf.xml
loadrt lcec

# Загрузка дополнительных HAL компонентов
loadrt siggen
loadrt or2
loadrt and2
loadrt not

# Создание thread с уникальным именем
loadrt threads name1=servo-thread period1=1000000 fp1=0

# Добавление функций в поток (правильный порядок)
addf motion-command-handler servo-thread  
addf motion-controller servo-thread
addf lcec.0.read servo-thread
addf lcec.read-all servo-thread
addf lcec.write-all servo-thread
addf lcec.0.write servo-thread

Hello again everyone,First, I apologize for the late reply — I’ve been working on revising my plan and wiring, and it took longer than expected.I’ve updated my wiring/architecture plan (see attached diagram), and here’s where I’m at:

• Mesa 7i92 over Ethernet
• Two 5-axis breakout boards (5ABOB ×2)
• DM556 drivers for NEMA34 motors (3.5 Nm, 3 A/phase)
• THC Proma 150 for torche height control (Arc OK, Up, Down signals)
• Relays for torch, laser, pump, etc.
• E-stop, limits, probe via optoisolators
• Power supplies: 5 V/8 A, 24 V/3 A, 36 V/12 A

On one BOB (P1) I plan to handle signals like Arc OK, Up, Down, E-stop, relays; on the other BOB (P2) I plan to handle limits, probe, and driver step/dir lines.Questions

1. With that setup (7i92 + 2 × 5ABOB), is the wiring architecture I’m proposing feasible?
2. I was thinking of starting with the G540 HAL/INI config in pncconf as a base, then editing it . Is that a sensible approach, or is there a better workflow to generate a clean HAL/INI for this sort of layout?

Thanks again to PCW, tommylight,  Your help is very valuable. Any further feedback or corrections before I begin wiring would be hugely appreciated.