Set up using AMC AB15A100 drives, brushed DC motor Prototrak Plus with Encoders

LinuxCNC is not finding the 7i77. I keep saying that.

The 5i25 is working. I don't think that the 7i77 is.

Do you see _any_ HAL pins with 7i77 in them? There were none last time you posted a pin list.

Rather than screenshots of the error message, press the "select all" button at the bottom, then copy and paste it here, or to a text file. There is important information off the top and bottom of the screen.

What we _can_ see is that there are no encoders on P2 either. What does your "loadrt hostmtot2" line in the HAL say?

andypugh, Many thanks!! These attached files show the pin out saved as .txt file. I also included the error file with a wire going from AMC SW-1 connector; pin 11 GND going to 7I77 CARD TB-3 connector 3 GND. When the encoders were counting, this was the wiring diagram (in the 1st post) at that time.Many thanks!

Edit: This 3rd attachment is error w/o GND wire going to TB-3; everything else is the same. If you compare this part of the file that has GND to TB-3 this has encoder info: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): ./LinuxCNC.hal
hm2: loading Mesa HostMot2 driver version 0.15
hm2_pci: loading Mesa AnyIO HostMot2 driver version 0.7
hm2_pci: discovered 5i25 at 0000:04:04.0
hm2/hm2_5i25.0: Smart Serial Firmware Version 43
hm2/hm2_5i25.0: 34 I/O Pins used:
hm2/hm2_5i25.0: IO Pin 000 (P3-01): IOPort
hm2/hm2_5i25.0: IO Pin 001 (P3-14): IOPort
hm2/hm2_5i25.0: IO Pin 002 (P3-02): IOPort
hm2/hm2_5i25.0: IO Pin 003 (P3-15): IOPort
hm2/hm2_5i25.0: IO Pin 004 (P3-03): IOPort
hm2/hm2_5i25.0: IO Pin 005 (P3-16): IOPort
hm2/hm2_5i25.0: IO Pin 006 (P3-04): IOPort
hm2/hm2_5i25.0: IO Pin 007 (P3-17): Muxed Encoder Select #0, pin Mux Select 0 (Output)
hm2/hm2_5i25.0: IO Pin 008 (P3-05): Muxed Encoder #0, pin Muxed A (Input)
hm2/hm2_5i25.0: IO Pin 009 (P3-06): Muxed Encoder #0, pin Muxed B (Input)
hm2/hm2_5i25.0: IO Pin 010 (P3-07): Muxed Encoder #0, pin Muxed Index (Input)
hm2/hm2_5i25.0: IO Pin 011 (P3-08): Muxed Encoder #1, pin Muxed A (Input)
hm2/hm2_5i25.0: IO Pin 012 (P3-09): Muxed Encoder #1, pin Muxed B (Input)
hm2/hm2_5i25.0: IO Pin 013 (P3-10): Muxed Encoder #1, pin Muxed Index (Input)
hm2/hm2_5i25.0: IO Pin 014 (P3-11): Muxed Encoder #2, pin Muxed A (Input)
hm2/hm2_5i25.0: IO Pin 015 (P3-12): Muxed Encoder #2, pin Muxed B (Input)
hm2/hm2_5i25.0: IO Pin 016 (P3-13): Muxed Encoder #2, pin Muxed Index (Input)
hm2/hm2_5i25.0: IO Pin 017 (P2-01): IOPort
hm2/hm2_5i25.0: IO Pin 018 (P2-14): IOPort
hm2/hm2_5i25.0: IO Pin 019 (P2-02): IOPort
hm2/hm2_5i25.0: IO Pin 020 (P2-15): IOPort
hm2/hm2_5i25.0: IO Pin 021 (P2-03): IOPort
hm2/hm2_5i25.0: IO Pin 022 (P2-16): IOPort
hm2/hm2_5i25.0: IO Pin 023 (P2-04): IOPort
hm2/hm2_5i25.0: IO Pin 024 (P2-17): IOPort
hm2/hm2_5i25.0: IO Pin 025 (P2-05): IOPort
hm2/hm2_5i25.0: IO Pin 026 (P2-06): IOPort
hm2/hm2_5i25.0: IO Pin 027 (P2-07): IOPort
hm2/hm2_5i25.0: IO Pin 028 (P2-08): IOPort
hm2/hm2_5i25.0: IO Pin 029 (P2-09): IOPort
hm2/hm2_5i25.0: IO Pin 030 (P2-10): IOPort
hm2/hm2_5i25.0: IO Pin 031 (P2-11): IOPort
hm2/hm2_5i25.0: IO Pin 032 (P2-12): IOPort
hm2/hm2_5i25.0: IO Pin 033 (P2-13): IOPort
hm2/hm2_5i25.0: registered
hm2_5i25.0: initialized AnyIO board at 0000:04:04.0
Shutting down and cleaning up LinuxCNC...
Running HAL shutdown script
Killing task linuxcncsvr, PID=2493
hm2_5i25.0: dropping AnyIO board at 0000:04:04.0
hm2/hm2_5i25.0: unregistered
hm2_pci: driver unloaded
hm2: unloading
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments

Debug file information:
Note: Using POSIX realtime
./LinuxCNC.hal:57: Pin 'hm2_5i25.0.7i77.0.1.analogout0' does not exist

Compare to the same area with GND connected, one has no encoder info.

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/share/linuxcnc/tcl/msgs
INIVAR=inivar
HALCMD=halcmd
LINUXCNC_EMCSH=/usr/bin/wish8.6
LINUXCNC - 2.7.8
Machine configuration directory is '/home/emc/linuxcnc/configs/LinuxCNC'
Machine configuration file is 'LinuxCNC.ini'
INIFILE=/home/emc/linuxcnc/configs/LinuxCNC/LinuxCNC.ini
PARAMETER_FILE=linuxcnc.var
TASK=milltask
HALUI=halui
DISPLAY=axis
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): ./LinuxCNC.hal
Shutting down and cleaning up LinuxCNC...
Running HAL shutdown script
Killing task linuxcncsvr, PID=2852
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments

Debug file information:
./LinuxCNC.hal:7: waitpid failed /usr/bin/rtapi_app hostmot2
./LinuxCNC.hal:7: /usr/bin/rtapi_app exited without becoming ready
./LinuxCNC.hal:7: insmod for hostmot2 failed, returned -1
2852
  PID TTY      STAT   TIME COMMAND

It appears to me that w/o having GND (from encode/ TB-3) to AMC SW-1 pin 11 (GND) shows encoder. My thinking was that the encoders needed their own GND wire. In addition, when the only thing that worked was the DRO had the GND wire to TB-3.

The encoders working doesn't tell us anything, as they are passively connected directly to the 5i25.
We are not seeing any sign of the 7i77 onboard processor working.

Attach your HAL and INI files.

andypugh, Many Thanks. The .ini and . hal are attached.

So, you are not actively disabling any smart-serial channels, but clearly no smart-serial devices are being detected.

This has to be one of:

No power to the smart-serial subsystem
No connection to the smart-serial subsystem (ie, DB25 cable not fully wired, or misswired)
7i77 in setup mode[1]
7i77 broken.

What LEDs are visible on the 7i77? Do any flicker as LinuxCNC is booted?


[1]

SETUP/OPERATE MODE
The 7I77 field I/O and Analog output processors can run in setup mode or operate
mode. In setup mode, the serial interface baud rate is fixed at 115.2 KBaud. In the operate
mode, the baud rate is set to 2.5M baud (default). Setup mode is also less critical of host
interface timing and enables a normal PC to communicate with the 7I77 for setup and
firmware update purposes. W4 controls the setup/operate mode selection for the Analog
processor and W12 controls the setup/operate mode selection for the isolated field I/O
processor. The jumpers must be in the "operate" mode for normal operation.
W4,W12 MODE BAUD RATE
LEFT Operate mode 2.5M baud (default, can be changed)
RIGHT Setup Mode 115.2K baud (fixed)

andypugh, Thank you!! The LEDs are yellow, no blinking-steady. The W4 & W12 are to the left (towards the P1 host connector). I can do continuity on the DB25 cable, all to be strait threw.
What else can I check? New 7i77 card in my future?

Many thanks!