Non Tormach Path Pilot Stuck at E-Stop

I am working on upgrading a non tormach router running a 5i25 and 7i76 combo with LCNC to Path Pilot.

After a handful of HAL changes to the 1100-3 HAL, the program starts up, but will not come out of E-stop when I hit the soft Reset button, and I don't have a physical reset button.

I would like to leave the physical wiring on the router side of things as-is, and modify the tormach_mill_mesa.hal file to retain the PP functionality and the machine side setup as much as possible.

I’m tempted to go in and wholesale replace the tormach HAL file with the router’s, but don’t want to lose functionality from PP or over complicate things.

I’m attaching both of the HAL files and the pathpilot log file excerpt here in the hopes that someone can help me get this thing out of E-stop so I can start modifying the homing and stepper settings. I’m getting the “Failed to bring machine out of E-stop. Please check machine power or DB-25 communication cable from the controller to the machine.” error message.

All help is greatly appreciated!

Mr. Technical

Also, you would not use _any_ 5I25 GPIO with a 5I25/7I76 configuration
as all general purpose inputs would be field I/O like:

hm2_5i25.0.7i76.0.0.input-00

Thanks for the replies.
Tommy, that is correct. On the original 5i25/7i76 setup hm2_5i25.0.gpio.006.in works fine. Estop was/(is)wired there.

I need to modify the tormach_mesa_mill Hal file to point there as well, but I don’t know if I can just point it there without breaking the debounce.

Peter, taking into account your and Tommy’s comments, would the following work?

In the tormach HAL I comment out:
net machine-ok-raw <= hm2_[HOSTMOT2](BOARD).0.gpio.003.in-not => debounce.0.3.in

and replace it with:
net machine-ok-raw <= hm2_[HOSTMOT2](BOARD).0.7i76.0.0.input-006.in-not => debounce.0.3.in

That’s my best guess based on your and Peter’s input. Sorry, it’s been years since I messed with this stuff.

Update,

I fixed the original HAL on PC 1, so now an external E-Stop button press trips a software E-Stop as well and kills the drives. I must have been experimenting years ago and forgot to test it.
The corrected line looks like:
net estop-ext <= hm2_5i25.0.7i76.0.0.input-06


On PC 2 (Path Pilot test bed), I’m now getting the following message in the pathpilotlog.txt file after it aborts:
Tormach_mill_mesa.hal:287: Pin ‘hm2_5i25.0.7i76.0.0.input-06’ does not exist

Oddly enough, running it from the operator login multiple times in a row will give me alternating results.

One time it will throw the following message on the notebook screen:
hm2/hm2_5i25.0:Smart serial card hm2_5i25.0.7i76.0.0 error =(8)
Remote fault

and the next time it will not even open the interface.

Third time reverts to the first error message.

What am I doing wrong?

Sounds like an issue with the 7I76 field or 5V power