LinuxCNC not starting

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22 Mar 2014 02:16 #45053 by Jerre122
Hi,

My CNC machine runs LinuxCNC with a Mesa 5i25 and 7i77 card.
Earlier today I booted my computer and linuxCNC. I wanted to change something in axis itself so I closed linuxCNC.
After having made the changes I copied the axis files to the correct directory (I change the code in a copy, not directly where its used by linuxCNC).
When I then started linuxCNC I received the following error:
Print file information:
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/realtime-2.6.32-122-rtai/modules/linuxcnc
LINUXCNC_CONFIG_DIR=
LINUXCNC_LANG_DIR=/usr/share/linuxcnc/tcl/msgs
INIVAR=inivar
HALCMD=halcmd
LINUXCNC_EMCSH=/usr/bin/wish8.5
LINUXCNC - 2.5.3
Machine configuration directory is '/home/linuxcnc/linuxcnc/configs/Abene_CNC'
Machine configuration file is 'Abene_CNC.ini'
INIFILE=/home/linuxcnc/linuxcnc/configs/Abene_CNC/Abene_CNC.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
Shutting down and cleaning up LinuxCNC...
Running HAL shutdown script
Killing task linuxcncsvr, PID=1196
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments
Cleanup done

Debug file information:
Can not find -sec MOT -var MOT -num 1 
Can not find -sec IO -var IO -num 1 
Can not find -sec LINUXCNC -var NML_FILE -num 1 
Can not find -sec EMC -var NML_FILE -num 1 
insmod: error inserting '/usr/realtime-2.6.32-122-rtai/modules/linuxcnc/hm2_pci.ko': -1 Invalid parameters
Abene_CNC.hal:9: exit value: 1
Abene_CNC.hal:9: insmod failed, returned -1
See the output of 'dmesg' for more information.
1196
  PID TTY      STAT   TIME COMMAND
Stopping realtime threads
Unloading hal components

Kernel message information:
[   19.213544] I-pipe: Domain RTAI registered.
[   19.213560] RTAI[hal]: <3.8.1> mounted over IPIPE-NOTHREADS 2.6-03.
[   19.213566] RTAI[hal]: compiled with gcc version 4.4.3 (Ubuntu 4.4.3-4ubuntu5) .
[   19.213640] RTAI[hal]: mounted (IPIPE-NOTHREADS, IMMEDIATE (INTERNAL IRQs DISPATCHED), ISOL_CPUS_MASK: 0).
[   19.213646] PIPELINE layers:
[   19.213654] f9424e20 9ac15d93 RTAI 200
[   19.213661] c085cb20 0 Linux 100
[   19.591962] RTAI[malloc]: global heap size = 2097152 bytes, <BSD>.
[   19.628087] RTAI[sched]: IMMEDIATE, MP, USER/KERNEL SPACE: <with RTAI OWN KTASKs>, kstacks pool size = 524288 bytes.
[   19.628105] RTAI[sched]: hard timer type/freq = APIC/12468620(Hz); default timing: periodic; linear timed lists.
[   19.628113] RTAI[sched]: Linux timer freq = 250 (Hz), TimeBase freq = 2593380000 hz.
[   19.628120] RTAI[sched]: timer setup = 999 ns, resched latency = 2944 ns.
[   19.628289] RTAI[usi]: enabled.
[   19.970455] RTAI[math]: loaded.
[   21.212208] hm2: loading Mesa HostMot2 driver version 0.15
[   21.290748] hm2_pci: loading Mesa AnyIO HostMot2 driver version 0.7
[   21.290817] hm2_pci 0000:05:09.0: PCI INT A -> GSI 18 (level, low) -> IRQ 18
[   21.290826] hm2_pci: discovered 5i25 at 0000:05:09.0
[   21.290922] hm2/hm2_5i25.0: invalid cookie, got 0xFFFFFFFF, expected 0x55AACAFE
[   21.290932] hm2/hm2_5i25.0: FPGA failed to initialize, or unexpected firmware?
[   21.290942] hm2_5i25.0: board fails HM2 registration
[   21.290975] hm2_pci 0000:05:09.0: PCI INT A disabled
[   21.290990] hm2_pci: probe of 0000:05:09.0 failed with error -22
[   22.978248] hm2: unloading
[   23.204978] RTAI[math]: unloaded.
[   23.342561] SCHED releases registered named ALIEN RTGLBH
[   23.377489] RTAI[malloc]: unloaded.
[   23.477026] RTAI[sched]: unloaded (forced hard/soft/hard transitions: traps 0, syscalls 0).
[   23.482383] I-pipe: Domain RTAI unregistered.
[   23.482478] RTAI[hal]: unmounted.

I then changed axis back to a previous backup (made just the day before, when it was still working) but the error remains.
Has anyone got an idea why the error occurs? It worked merely minutes before.

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22 Mar 2014 02:52 #45058 by PCW
Replied by PCW on topic LinuxCNC not starting
Looks like a bad 5I25, or bad/dirty PCI slot (a possible address error)

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22 Mar 2014 03:52 #45066 by Jerre122
Replied by Jerre122 on topic LinuxCNC not starting
It seems unlikely that the PCI slot or 5I25 suddenly stops working since I haven't touched the PC and Linuxcnc has been working for some months.
I will check it. I also wanted to run mesaflash but for some reason I can't run it.
If I doubleclick mesaflash the computer complains it can't execute that type of file.
And when I use the terminal:
linuxcnc@linuxcnc-desktop:~/Downloads/5i25/utils/linux$ mesaflash
mesaflash: command not found
is printed.
How can I get mesaflash to work?

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22 Mar 2014 03:55 #45067 by PCW
Replied by PCW on topic LinuxCNC not starting
I would try the 5i25 in another CPU to see if its a 5I25 or CPU problem

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22 Mar 2014 16:48 #45089 by Jerre122
Replied by Jerre122 on topic LinuxCNC not starting
Switching the card to another PCI slot worked. :)
Still strange considering I didn't touch it.

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23 Mar 2014 02:51 #45108 by andypugh
Replied by andypugh on topic LinuxCNC not starting

It seems unlikely that the PCI slot or 5I25 suddenly stops working since I haven't touched the PC and Linuxcnc has been working for some months.


I actually had the very same problem yesterday. Re-inserting the PC card fixed it.

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26 Mar 2014 02:56 #45254 by Jerre122
Replied by Jerre122 on topic LinuxCNC not starting
I have the same problem again. But this time switching to another slot doesn't fix it. Could this be a problem with the PC itself or with the Mesa card? This is really annoying since the PC is in a place that is not easily accessible. Apart from this I also have a lot of milling work to do. I did blow out the pci slot before changing slots.

I hope it is just the PC and not the Mesa card.

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26 Mar 2014 04:05 #45257 by PCW
Replied by PCW on topic LinuxCNC not starting
I have seen this before when the computer 3.3V is marginal, you might check your power supply 3.3V

(what happens is that the 5I25 is reset by low 3.3V so the card is there and findable by lspci but has not been enabled by the BIOS startup)

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27 Mar 2014 05:20 - 27 Mar 2014 05:21 #45289 by Jerre122
Replied by Jerre122 on topic LinuxCNC not starting
lspci did indeed still find the card. I don't have to reset the pc to have this problem though. I just restarted Linuxcnc.
Today I started the machine again and for some reason it was working again. I did some jogging and everything seemed fine. After doing something else for about 35 minutes (Linuxcnc was still running) I switched from jogging to handwheel. I moved maybe 2cm and suddenly everything stopped, I got some RT errors and connection errors ( I forgot to take a screenshot). Trying to restart linuxcnc and the PC gave the same error as before.

I will try using another PC tomorrow.
Last edit: 27 Mar 2014 05:21 by Jerre122.

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27 Mar 2014 06:01 #45290 by PCW
Replied by PCW on topic LinuxCNC not starting
I would also measure the power supply 3.3V

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