(Solved) Initialization code for a rintelligent ECT60 fails when run on an ECR60

I followed your suggestions and am running into the following errors:

Machine configuration directory is '/home/kurt/linuxcnc/configs/BaxEDM-2axis-WireEDM'
Machine configuration file is '2axis-WireEDM.ini'
INIFILE=/home/kurt/linuxcnc/configs/BaxEDM-2axis-WireEDM/2axis-WireEDM.ini
VERSION=1.1
check_config: Unchecked: [KINS]KINEMATICS=baxkins
PARAMETER_FILE=baxedm_mm.var
TPMOD=
HOMEMOD=
TASK=milltask
HALUI=halui
DISPLAY=axis
COORDINATES=XYZ
KINEMATICS=baxkins
Starting LinuxCNC...
Starting LinuxCNC server program: linuxcncsvr
Loading Real Time OS, RTAPI, and HAL_LIB modules
Starting LinuxCNC IO program: io
libnml/buffer/shmem.cc 320: Shared memory buffers toolCmd and toolCmd may conflict. (key=1004(0x3EC))
libnml/buffer/shmem.cc 320: Shared memory buffers toolSts and toolSts may conflict. (key=1005(0x3ED))
libnml/buffer/shmem.cc 320: Shared memory buffers emcError and emcError may conflict. (key=1003(0x3EB))
emc/iotask/ioControl.cc 786: can't load tool table.
Starting HAL User Interface program: halui
linuxcnc TPMOD=tpmod HOMEMOD=homemod EMCMOT=motmod
Found file(REL): ./2axis-WireEDM.hal
Shutting down and cleaning up LinuxCNC...
*** baxkins.comp setup ok
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments

Debug file information:
Note: Using POSIX realtime
./2axis-WireEDM.hal:51: Pin 'lcec.0.0.actual-velocity' does not exist
5318
Stopping realtime threads
Unloading hal components
Traceback (most recent call last):
  File "/home/kurt/linuxcnc/configs/BaxEDM-2axis-WireEDM/baxuipushbuttons.py", line 168, in <module>
Traceback (most recent call last):
  File "/home/kurt/linuxcnc/configs/BaxEDM-2axis-WireEDM/baxmisc.py", line 462, in <module>
    while True:
KeyboardInterrupt
    time.sleep(0.01)
KeyboardInterrupt
baxkinsdata: not loaded
<commandline>:0: exit value: 255
<commandline>:0: rmmod failed, returned -1
<commandline>:0: unloadrt failed
Note: Using POSIX realtime

I went back and carefully made the mods again, in case I missed something, but it still reports errors. Through a great deal of trial and error, I found that some of the configurations marked for removal must remain in the XML file for the program to run without error. Deleting any of the 0x60xx vars below cause many errors. Regardless, even with all the other mods in place, it's still stuck at "PrOp."

      <slave idx="0" type="generic" vid="00000a88" pid="0A880002" configPdos="true">
         <dcConf assignActivate="300" sync0Cycle="*1" sync0Shift="0" />
         <sdoConfig idx="60FE" subIdx="2"> <!-- -->
            <sdoDataRaw data="00 00 03 00" /> <!-- set the bit mask for out1 and out2 (bit 16 and 17 should be 1) -->
         </sdoConfig>
         <!-- Note: 0x2007 address default value is 0x00000006, not what the manual claims -->     
         <syncManager idx="2" dir="out">
            <pdo idx="1600">
               <pdoEntry idx="60FE" subIdx="1" bitLen="32" halPin="set60FE-1" halType="u32" />
               <pdoEntry idx="6040" subIdx="00" bitLen="16" halPin="cia-controlword" halType="u32" />
               <pdoEntry idx="6060" subIdx="00" bitLen="8" halPin="opmode" halType="s32" />
               <pdoEntry idx="607A" subIdx="00" bitLen="32" halPin="target-position" halType="s32" />
           </pdo>
         </syncManager>
         <syncManager idx="3" dir="in">
            <pdo idx="1a00">
               <pdoEntry idx="6041" subIdx="00" bitLen="16" halPin="cia-statusword" halType="u32" />
               <pdoEntry idx="6061" subIdx="00" bitLen="8" halPin="opmode-display" halType="s32" />
               <pdoEntry idx="6064" subIdx="00" bitLen="32" halPin="actual-position" halType="s32" />
               <pdoEntry idx="60FD" subIdx="00" bitLen="32" halPin="digital-inputs" halType="u32" />
            </pdo>
         </syncManager>
      </slave>
 

Can you comment out nets and things in the hal file to also remove the digital in and out?
rodw also mentioned doing a factory reset of the drive by writing to a sdo. Can you do that too?

I will try that, yes. What is meant by "nets and stuff?"

I will also try the factory reset but am unsure how well that will work. What I mean is, let's say that I issue the factory reset command upon entry to the code. Then, the following code will immediately configure the driver into a "not factory reset" condition. Is the thinking that something was changed that has not been corrected and that a factory reset is the only way to fix it?

I specifically was after the digital IO like herePut a # in front of the net lines. "and stuff" is vague for anything else that might cause problem for linuxcnc to start.
The logic of your machine is not correct then, but that's not important now. Get it to start only.
 

Understood. I tried the above - no change, status light still blinking, still in "PREOP".

Regarding a factory reset, I'm not sure how to apply it. See attached screenshot:

FWIW, here are the files in question as of now, with the requested lines commented out or removed. I must still be missing something - or the manual leaves out critical information...

Do you have the errors from syslog?

I would like to see the 60fe and 60fd sdos and pdos out specifically and only the 6 mentioned PDOs in there.

Here is a document on how to use the drive in TwinCAT.
shopcdnpro.grainajz.com/category/409767/...%8D%97-%E8%8B%B1.pdf
I guess it is worthwhile to check it works there.

No change.
How do I access and view syslog?
 

I checked the link you provided and find the note on page 16 interesting: "... This index 0x2001 only works on ECR60. If you change it on ECT60, please find index 0x2020..."
The developer of my code intended it to be loaded into an ECT60 (closed loop) driver and configured it for an open loop stepper. Given the above statement (if true), it's odd that he sets up register 2001 but not register 2020.
<sdoConfig idx="2001" subIdx="0"> <!-- segmentation/resolution for open loop -->
            <sdoDataRaw data="40 9C" /> <!-- 40000 counts/rev -->

"For fun", I tried adding this back into ethercat-config.xml, but the error condition remains.

I looked into downloading the package onto my Windows PC but it's unclear which download to use. They have quite a few and the link just goes to their front page, not to a specific download screen. To be honest, I don't hold out much hope that dropping it in place of my config file will make it work, but as you alluded to, perhaps it contains something the manual left out. Anyway, their comment above makes me wonder all the more whether there is key documentation missing from the User Manual regarding differences between the ECR and ECT drivers... sigh.