need help 5i25/7i76 setup for plasma

kb8wmc wrote: Rod, thank you much for your information and suggestions...I appreciated it...I am still working on the getting a limit switch working, I think my problem is in my HAL setup...
Thanks again...

kb8wmc

Connect your input to limit-X in HAL, but don't forget the check the limit switch entries in the ini file. That will determine if and how they work.

My progress thus far...
I now have two motors connected and operational for testing...connected three home/limit switches in series NC configuration...I removed or commented out all parallel port references, so that I have only made reference in hal and ini files to connections and hardware to be recognized via 5i25/7i76 Mesa...Initially had problems with the actual names of the pins that were relevant to the limit/home switches...I was able to remedy the improper names and spelling by reading lots of posts in the forums...I learned quite a bit about how the actual component names work and relate to HAL...BUT, along the path of learning I found that what is called out and used generally for the naming conventions to be used by HAL, (e.g. hm2_5i25.0.7i76.0.0.input-00) does not work with my boards....Instead I have to identify by the number of the gpio pin in order not to get a complaining error about no such pin, (e.g. hm2_5i25.0.gpio.004.in)...
At present my limit switch is being provided field power and when checked with multimeter is functioning properly...One leg to field power terminal 2 and the other to TB6 pin 004...The problem is that the when I test the homing function the switch does not perform the homing function...I can see the switch in HAL show, but no change occurs when I trip the lever...
I feel there is something that I am missing like a setp something or other, but I can find no examples in my searching for answers...I am almost at my wits end...Any guidance will be appreciated...

The GPIO pins on a 5I25/7I76 interface are not of _any_ use

You must use the hm2_5i25.0.7i76.0.0.input-xx pins to use the field I/O inputs

if the hm2_5i25.0.7i76.0.0.input-xx pins are not present this is usually some kind of hardware setup issue
common problems:

1. No 5V to 7I76 ( set 5I25 to supply 5V to 7I76 and 7I76 to get 5V from --> 5I25 = 5I25 W2 up, 7I76 W2 left )
2. No field power at startup
3. 7I76 Setup/operate jumper in setup mode (must be in operate mode)
4. Wrong firmware in 5I25 (check with mesaflash)
5. 7I76 not connected to 5I25 P3 with IEEE1284 cable

PCW,
Your information solved my limit/home switch problem....The W3 jumper was set to setup mode...I switched it to operate mode and it works as it should now....Next will be the touch-off/probe for the torch and the emergency stop switch...
The commands code now looks like everyone else's examples of code...Will keep informed of my progress...
Thank you so much PCW

Thanks to the input from folks I have motion of the machine with active home/limit switches...
This is 5i25/7i76 ---- THCAD-10

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Hypertherm PowerMax 45
Presently at the point where we need some guidance on connecting the six wire + ground coming from the PM45 into the THCAD-10 and whatever else...We can identify where the +IN and -IN from the PM45 attach to the terminals on the THCAD-10, but there are 4 other wires and a ground wire that go someplace, but I am not clear to where they attach...
Any direction will be appreciated....

I think this recent thread is what you need.
forum.linuxcnc.org/plasma-laser/33226-th...-hypertherm-45-nonxp