Retrofit of 2 Messer Cortina DS Plasma cutting machines

Wires are cut, a bunch is removed, the drive box with Mesa 7i77 and 2 power supplies attached to it is also installed inside the existing console, PC with Mesa 6i25 installed and everything wired and tested, so today was encoder wiring and tuning day!
Took some running back and forth over the machine to disengage and engage the Y2 motor twice, but all three drives are tuned and running!
Was a good day for tuning, also managed to tune the Mazak X and Z motors drives.
Tomorrow more "removing cabling" and extending one of the encoder cables, i cut it to short, shame on me, then removing the existing Z axis motors (has 2 Z axis), trying to shoehorn a stepper motor, add a drive for it and another power supply, wire in the THCAD... hmmm with 2 to 4 hour days, to much???
I should do some pictures and videos, i think...

Sorry for the delay, the second one was finished quite a while back in 2022, but still waiting for the plasma source to do the final tuning and testing.
Also, the machine has been moved to another place in the shop, so aligning the rails is taking forever for them. I did warn them that the rails were off by quite a bit in the old place as i did notice that during tuning of the tandem axis.
Anyone need a 400A Hypertherm plasma source for cheap in Europe?

Still waiting for the plasma source, the one they got has no pilot arc.
Told them i can probably make it work but wont be reliable to start, so they told me to wait some more for a better one.
They are very pleased with the new Hypertherm 40A they got for the other machine, but at 3700 Euro and very expensive consumables, trying to find something more affordable.

Attached both configs to the third post.

Cr@p forgot to update this, finished the second one and in production use daily.
There was a change in the meantime, those are not 2 separate machines anymore, when moved from the other shop here, the owner had the great idea of having 2 gantries on one set of rails, so now it is a dual gantry machine, both sides can do 6X2.5M but not at the same time, one can do 6 while the other can do 2X2.5M at the same time, can be done from both sides as needed.
Will take some pictures next time i am there, it is closer to me now, about 2KM.

Hello everyone,
first of all I don't know if I'm in the right place in the frum, but if I need to move my message please let me know.

Like you, I am in the process of retrofitting my 5-axis CNC type XYZBC.
In fact, having important torque reducers on the B&C axes I want to add encoders directly on these two axes. For this, I have started to buy a 7i96s where only one encoder is available but a daughter board can be added like a 7I85.
I've started to connect the system under linuxcnc 2.9.3, and I can't synchronize the scale between the Axis display and the actual position of my encoder.
my encoder is 1000 pulses/hole in quadrature, which gives 4000 pulses per revolution. With variables SCALE_ENCODEUR = 11.11 I manage to synchronize the display & the actual position of my axis; unfortunately my “joint” doesn't follow; I need at least a value of 3000 pulses/hole to no longer have this “joint tracking error”. And even with this value, the motor remains very reactive to the slightest movement of my encoder. Of course, the display no longer corresponds (since there's only the value of 11.11 to synchronize the display and the position of my axis).

I've been struggling for two months just to get this setting right.

Does anyone have an idea for my problem?

Thanks in advance for your help