No Z Motion On Probe or Probe Test - DRO Indicates Motion

Mesa 7i96, Gecko G540 on P1 expansion connector, and THCAD on TB2 encoder0. No other inputs and outputs connected to or configured for 7i96 yet. X, Y, Z, torch relay (G540 Output1), z switch sensor (G540 Input1), and volts via. encoder all working correctly before and after plasmac configuration. Everything works correctly manually from plasmac interface via. buttons (except Probe Test) or keyboard. G0/G1 Z motion works correctly from MDI.

M3 $0 S1 or Probe Test button begins probe sequence, DRO indicates Z motion until soft limit/error, but Z axis doesn't move.

Activating z switch sensor it passes probe height stops the indicated Z motion, or raises correct error if activated too high.

Any help would be greatly appreciated!

No, I was thinking the same thing and looked at Z step input to G540. Nothing.

Attached hal, ini, and pins. Some of the limits and velocities were changed. Second issue arises after probe attempts and(?) on-screen E-Stop - keyboard Up/Down keys will often move (only) the second Y (Joint 2) motor. Limit, Ohmic, E-Stop, and feedhold switches, relays, etc. still attached to ESS/TMC3in1, that Mesa components are replacing, and will latter be moved to 7i96 I/O.

Thank you!

tommylight wrote:

During probing, does the machine make high pitched noise ?

What causes the high pitched noised? Is it just a stepper motor thing? My new steppers make a higher pitched noise when z axis is probing.

PCW spun firmware that allows painless/temporary swap of IDC<->DB25 cable between 7i96 and existing/working Ethernet SmoothStepper. Only Z sensor and torch relay connected to the G540 on other end of cable so no other I/O accessible after swap.

Table in use daily with Mach3, ESS, TMS3in1 THC, and large/clean linear power supply. Testing 7i96 involves just cable swap (above) and network cable. Tried other PC's with fresh LinuxCNC/Plasmac installs. Tried second known good cable. Tried other known good ethernet cables. Tried with and without THCAD installed and/or configured. Swapped X and Z stepgen's and issues followed Z. Moved Z to stepgen not on P1 with IMS and Gecko drivers connected and issues followed Z. Tried several know good 5V power supplies - isolated or common ground with rest of electronics. Tried two other known good G540 controllers. Works fine with $2 parallel BOB and Mach3 or LinuxCNC. Tests good with another ESS and a USB SmoothStepper.

Working table, so after troubleshooting while 7i96 is installed for 1-2hrs/day for a week I'm certain that I've eliminated all hardware and wiring. Many, many people successfully running LinucCNC without issues and I suspect only that my configuration (probably something really simple) is to blame as this is first Mesa board install or configuration.

Absolutely have to eliminate Mach3 and SmoothStepper nighmare on plasma and 2 router tables...