Mill has been running fine for years, all of a sudden I get the following error

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2 years 5 hours ago #313552 by B.Reilly01
My mill has been running a very basic AXIS HAL and INI files and doing fine for years.  It is not connected to the internet, so it didn't do an unexpected update.  All of a sudden I get the following on start up:
Code:
Error report created by /usr/lib/tcltk/linuxcnc/show_errors.tcl: Print file information: RUN_IN_PLACE=no LINUXCNC_DIR= LINUXCNC_BIN_DIR=/usr/bin LINUXCNC_TCL_DIR=/usr/lib/tcltk/linuxcnc LINUXCNC_SCRIPT_DIR= LINUXCNC_RTLIB_DIR=/usr/lib/linuxcnc/modules LINUXCNC_CONFIG_DIR= LINUXCNC_LANG_DIR=/usr/lib/tcltk/linuxcnc/msgs INIVAR=inivar HALCMD=halcmd LINUXCNC_EMCSH=/usr/bin/wish8.6 LINUXCNC - 2.8.0~pre1 Machine configuration directory is '/home/cncmill/linuxcnc/configs/3500rpm_Hurco_SM1' Machine configuration file is '3500rpm_Hurco_SM1.ini' INIFILE=/home/cncmill/linuxcnc/configs/3500rpm_Hurco_SM1/3500rpm_Hurco_SM1.ini VERSION=1.1 PARAMETER_FILE=linuxcnc.var TASK=milltask HALUI=halui DISPLAY=axis COORDINATES=XYZ KINEMATICS=trivkins coordinates=XYZ Starting LinuxCNC... Starting LinuxCNC server program: linuxcncsvr Loading Real Time OS, RTAPI, and HAL_LIB modules Starting LinuxCNC IO program: io Starting HAL User Interface program: halui Found file(REL): ./3500rpm_Hurco_SM1.hal Shutting down and cleaning up LinuxCNC... Running HAL shutdown script hm2: loading Mesa HostMot2 driver version 0.15 hm2_pci: loading Mesa AnyIO HostMot2 driver version 0.7 hm2: unloading Removing HAL_LIB, RTAPI, and Real Time OS modules Removing NML shared memory segments Debug file information: Note: Using POSIX realtime hm2_pci: rtapi_app_main: No such device (-19) ./3500rpm_Hurco_SM1.hal:9: waitpid failed /usr/bin/rtapi_app hm2_pci ./3500rpm_Hurco_SM1.hal:9: /usr/bin/rtapi_app exited without becoming ready ./3500rpm_Hurco_SM1.hal:9: insmod for hm2_pci failed, returned -1 2986 Stopping realtime threads Unloading hal components Note: Using POSIX realtime ----------------------------------------------------------------------- Info report created by linuxcnc_info: The file:    /tmp/linuxcnc_info.txt can be posted to a forum or a web site like:      http://pastebin.com in order to provide information about the linuxcnc system and configuration.                 Date: Thu Oct 31 10:59:53 CDT 2024             UTC Date: Thu Oct 31 15:59:53 UTC 2024         this program: /usr/bin/linuxcnc_info               uptime: 10:59:53 up 4 min, 1 user, load average: 0.38, 1.12, 0.60      lsb_release -sa: LinuxMint Linuxcnc Uspace Powered by Linux Mint 19.2 Tina 19.2 tina       which linuxcnc: /usr/bin/linuxcnc                  pwd: /home/cncmill/linuxcnc/configs/3500rpm_Hurco_SM1                 USER: cncmill              LOGNAME: cncmill                 HOME: /home/cncmill               EDITOR:                VISUAL:              LANGUAGE: en_US                 TERM: dumb            COLORTERM:               DISPLAY: :0              DESKTOP: mate         display size: 1024x768 pixels (270x203 millimeters)                 PATH: /usr/bin:/home/cncmill/linuxcnc/configs/3500rpm_Hurco_SM1/bin:/usr/bin:/usr/local/sbin:/usr/local/bin:/usr/sbin:/usr/bin:/sbin:/bin:/usr/games:/usr/local/games:/snap/bin uname items:          nodename -n: CNC-Mill       kernel-name -s: Linux       kernel-vers -v: #1 SMP PREEMPT RT Thu Mar 5 00:02:34 AEDT 2020           machine -m: x86_64         processor -p: x86_64          platform -i: x86_64       oper system -o: GNU/Linux /proc items:              cmdline: BOOT_IMAGE=/boot/vmlinuz-4.19.106-rt44-lcnc root=UUID=69380275-e756-469f-a27d-d74d6649283d ro quiet splash vt.handoff=1           model name: Intel(R) Atom(TM) CPU D2550 @ 1.86GHz                cores: 2              cpu MHz: 1861.981              parport: 0000-0000 : parport0               serial: 0000-0000 : serial 0000-0000 : serial Versions:                  gcc: gcc (Ubuntu 7.5.0-3ubuntu1~18.04) 7.5.0               python: Python 2.7.17                  git: git version 2.17.1           git commit: NA                  tcl: 8.6                   tk: 8.6                glade: not_in_PATH           glade-gtk2: not_in_PATH linuxcnc_var all:      LINUXCNCVERSION: 2.8.0~pre1 LINUXCNC_AUX_GLADEVCP: /usr/share/linuxcnc/aux_gladevcp LINUXCNC_AUX_EXAMPLES: /usr/share/linuxcnc/aux_examples             REALTIME: /etc/init.d/realtime                  RTS: uspace           HALLIB_DIR: /usr/share/linuxcnc/hallib dpkg -l '*linuxcnc*': Desired=Unknown/Install/Remove/Purge/Hold | Status=Not/Inst/Conf-files/Unpacked/halF-conf/Half-inst/trig-aWait/Trig-pend |/ Err?=(none)/Reinst-required (Status,Err: uppercase=bad) ||/ Name                Version                      Architecture Description +++-===================-============================-============-===================================================================== un  linuxcnc            <none>                       <none>       (no description available) un  linuxcnc-dev        <none>                       <none>       (no description available) un  linuxcnc-doc        <none>                       <none>       (no description available) ii  linuxcnc-doc-en     1:2.8.0~pre1.5821.g7525a1528 all          motion controller for CNC machines and robots (English documentation) un  linuxcnc-sim        <none>                       <none>       (no description available) un  linuxcnc-sim-dev    <none>                       <none>       (no description available) ii  linuxcnc-uspace     1:2.8.0~pre1.5821.g7525a1528 amd64        motion controller for CNC machines and robots ii  linuxcnc-uspace-dev 1:2.8.0~pre1.5821.g7525a1528 amd64        PC based motion controller for real-time Linux

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2 years 4 hours ago #313555 by PCW
hm2_pci: rtapi_app_main: No such device (-19)


Looks like the PCI card is not found, common issues
are dirty slots, (clean card edge connector and slot with 99% isopropanol),
on 5I25/6I25: low 3.3V from PC power supply (replace PC power supply),
failed PC, failed PCI card.

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2 years 1 hour ago #313560 by B.Reilly01
Thanks for the quick response, looks like it's the 5i25 card. There were no LEDs on on the card, so I unplugged it and reseated it. The init and /Done leds flickered and went out. So I took it to another PC, same behavior,

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1 year 11 months ago #313568 by tommylight
Use alcohol to clean the pins on the 5i25 card and inside the PC slot, use an old cotton t-shirt for the first and an old tooth brush for the second, leave to dry for an hour or use compressed air to dry faster, then plug in.
Also use a voltmeter and measure on the main 20 or 24 pin mainboard connector between any of the black wires and an orange wire, it should be 3.3V, anything lower than 3.1 will probably not work, PCW knows this best.

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1 year 11 months ago #313636 by B.Reilly01
After reading the manual again, it looks like there shouldn't be any LEDs on. I cleaned everything up and plugged it back in and now Mesaflash can see it again.

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