Error,

This should help with what I can't describe.

drive.google.com/file/d/1X3XSeql0a9D60dk...DrQ/view?usp=sharing

tjamscad wrote: This will allow LinuxCNC to load but when the machine is powered on the drives and contactors go crazy. The also causes a joint 2 following error. That is my Z axis.

This appears to be what is happening when I turn the machine on.

If you have schematics, you should really check for voltage drop on the 24V rail, and the mains power drop.
Also check for anything shorted on the 24V side. Start disconnecting things and testing, one by one.
That is a no god state as that switching on and off will mess up something else.

I dont know when these were done or how acuret they are but here they are.

drive.google.com/file/d/0B86EwtSOzbrjNHN...NkE/view?usp=sharing

In your video one of the contactors is sparking a lot, so check what it is connected to or disconnect the output wires from it.
That might be the actual problem, but it also might not be, the sparking can be caused by an iductive load also.

If i comment out the XX axis PRDY line for X,Y and Z linuxCNC will boot and run I just can't move any axes.
####################################################################
#
# MACHINE ON
#
# connections to start machine when MACHINE ON is pressed
#
net MachineIsOn <= motion.motion-enabled
net MachineIsOn => ppmc.0.dout.00.out # X ax is drive enable
net MachineIsOn => ppmc.0.dout.01.out # X axis PRDY
net MachineIsOn => ppmc.0.dout.02.out # Y axis drive enable
net MachineIsOn => ppmc.0.dout.03.out # Y axis PRDY
net MachineIsOn => ppmc.0.dout.04.out # Z axis drive enable
net MachineIsOn => ppmc.0.dout.05.out # Z axis PRDY
net MachineIsOn => ppmc.0.dout.06.out # ESTOP
net MachineIsOn => ppmc.0.dout.10.out # hyd pump & spdl oil cooler
#
####################################################################

The relay that is sparking so much in the video is for the hydraulic pump.

Unfortunately, you are using non-standard board addresses, so the diagnostic program won't work properly.
The diagnostic is dumb, it will only test an encoder board at address 0, a DAC board at address 4 and a DIO board at address 6. So, if you change one of your encoder boards at a time to address 0, then you can test it with the commtest mode. Then, you can swap the address settings and try the other board.
If the commtest works OK, that will indicate that communication between the PC and the encoder boards is good.
If the commtest does not give a no errors report, then you have to debug further.

Jon

Also note that the new version encoder boards take up 2 addresses, so when you have that one at address zero, there should be no board at address 1. My usual setup is encoder boards at addr 0 and 2, DACs at addr 4 and 5, and DIOs starting at addr 6.

Jon

I moved the card addresses and here are the results.

What are the dip switches combination for addressing? Is there a chart?

1-1-1-1 =0 ??