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tommylight wrote:

Usually omitting or deleting lines with HOME_...._velocity in the ini file and editing the homing and limit lines in hal is all it takes,

It's usual to retain the lines, but set the two velocities to zero. Omitting probably works too (they will default to zero) but actively setting to zero looks less like a mistake. 
 

endian wrote:

I have not using any kind of global variables 

I think you are, look at line 159:

mode_selection is a static global in the code. 

I don't know for sure if that is enough to cause the problem? 

it looks like mode_selection should be a local variable (actually, make it a parameter so that you can debug using it)

Also maybe consider using a "switch" command on mode_selection rather than repeated "if (mode_selection == ##) "

timo wrote:

 because I might have damaged a drive or two without beeing aware of the importance of the wiring.

 
A cage-clamp terminal done up nice and tight with the cable not actually inside the clamp is a popular way to blow up a drive. Give the wires a good tug after tightening the clamps.

Kieran wrote:

How's the rigidity of the harmonic drive? 

It seems OK. The HD website quotes values for torsional stiffness, but to be honest I don't know what value would be appropriate for a milling machine, so the numbers aren't useful to me. 

But I frequently use it just as a handy way to mount round stock and have noticed no issues. 
 

Here's an example:

 

It's a bit tricky because you do need to use muxed encoders for all
encoders (because the 7I89 uses physically muxed encoders)

 

Does this help at all?
wiki.linuxcnc.org/uploads/orient.svg
It's one potential way to do it.

Probably .hal and .comp which is overflowing

Excuse me for mess in the component but it is in the working session ...

I am sorry

I will enumerate all hard code and

Is has behaviour as I described higher ... I am confused and I have feeling like something in the working session is mixing together but no way to find it out...

Please let me know what I am doing wrong

thanks
regards E..

My experience is limited, but typicaly getting from a scan to a usable model is the hard part. I would ask for a demo with a sample component and be sure it goes all the way to the point that you expet to use the scan.