My Newb Plasma Table Attempted Build

I did ask if you are getting such errors, the reply was no.
Set the base thread to 100000.

I recall that, I did mention I got sidetracked yesterday...I apologize.

Its a 7I96 configuration so no base thread

Setting the servo thread to 2000000 might help (though laptops are not suggested in general)

In your hal file I would remove all statements like:

setp pid.x.maxerror .0005

and in your ini file I would set all ferror limits smaller
Currently they are:

FERROR = 0.5
MIN_FERROR = 0.05

which will mask fairly major setup issues with step generation
I would set them (all axis) to

FERROR = 0.01
MIN_FERROR = 0.001


In addition since you have a high latency host PC I would add

# latch stepgen feedpack position 200 usec before nominal read time:
setp hm2_7i96.0.dpll.01.timer-us -200
setp hm2_7i96.0.stepgen.timer-number 1

To your hal file

PCW wrote: In addition since you have a high latency host PC I would add

# latch stepgen feedpack position 200 usec before nominal read time:
setp hm2_7i96.0.dpll.01.timer-us -200
setp hm2_7i96.0.stepgen.timer-number 1

To your hal file

Does it matter where in the hal file, or is there a preferred part of it to insert this? I'm not ashamed to admit I'm super ignorant.

No, it does not matter where that's placed.
( though I tend to put global settings at the top of the file )

The only thing in hal files that is sensitive to order (AFAIK)
is the order of addf statements and loadrt statements where
one module depends on the other.

PCW wrote: No, it does not matter where that's placed.
( though I tend to put global settings at the top of the file )

The only thing in hal files that is sensitive to order (AFAIK)
is the order of addf statements and loadrt statements where
one module depends on the other.

I made all of those changes and it homes just fine. Then when I attempt to jog I immediately get a joint 1 and joint 2 following error.

Actually that's a good thing. it shows that the stepgen is not following the commanded position.
This usually means a setup error of some kind or a severe latency issue on the host PC.

If you made significant changes in the hal/ini files (in velocity or acceleration settings)
can you repost them?

PCW wrote: Actually that's a good thing. it shows that the stepgen is not following the commanded position.
This usually means a setup error of some kind or a severe latency issue on the host PC.

If you made significant changes in the hal/ini files (in velocity or acceleration settings)
can you repost them?

I reverted everything back to how it was after it went crazy trying to change them yesterday. They're the same as the ones I shared with you (attaching here again for convenience).

The per axis velocity and acceleration limits are higher than the stepgen velocity and
acceleration limits, This is the likely cause of the following errors. I would double the stepgen
velocity and acceleration limits and see if that fixes the errors.

Also set the steplen and stepspace to at least 5000, preferably 10000 until you have everything in working order.