Problem geting basic config running

Hi,
I am trying to get the configuration for my lathe set up as far as possible without having the physical hardware yet. I have done a very basic configuration, not using any extra interfaces as far as I know, yet the system wont start. I attach a zip file with my setup information and will paste below the output that Linux CNC asks me to include if asking for help. I have read through the start up guide and cannot see additional steps required although that may very well be where I am going wrong.

Thanks
Regards
Peet

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 - 2.5.1
Machine configuration directory is '/home/peet/linuxcnc/configs/BV20B-L'
Machine configuration file is 'BV20B-L.ini'
INIFILE=/home/peet/linuxcnc/configs/BV20B-L/BV20B-L.ini
PARAMETER_FILE=linuxcnc.var
TASK=milltask
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 TASK program: milltask
Starting DISPLAY program: axis
Shutting down and cleaning up LinuxCNC...
Killing task linuxcncsvr, PID=2081
Killing task milltask, PID=2136
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
custom_postgui.hal:15: Pin 'pyvcp.spindle-speed' does not exist
2081
PID TTY STAT TIME COMMAND
2136
PID TTY STAT TIME COMMAND
Stopping realtime threads
Unloading hal components

Kernel message information:
[ 946.362379] I-pipe: Domain RTAI registered.
[ 946.362383] RTAI[hal]: <3.8.1> mounted over IPIPE-NOTHREADS 2.6-03.
[ 946.362385] RTAI[hal]: compiled with gcc version 4.4.3 (Ubuntu 4.4.3-4ubuntu5) .
[ 946.362412] RTAI[hal]: mounted (IPIPE-NOTHREADS, IMMEDIATE (INTERNAL IRQs DISPATCHED), ISOL_CPUS_MASK: 0).
[ 946.362413] PIPELINE layers:
[ 946.362415] f8a3de20 9ac15d93 RTAI 200
[ 946.362417] c085cb20 0 Linux 100
[ 946.374147] RTAI[malloc]: global heap size = 2097152 bytes, <BSD>.
[ 946.374225] RTAI[sched]: IMMEDIATE, MP, USER/KERNEL SPACE: <with RTAI OWN KTASKs>, kstacks pool size = 524288 bytes.
[ 946.374229] RTAI[sched]: hard timer type/freq = APIC/6235800(Hz); default timing: periodic; linear timed lists.
[ 946.374232] RTAI[sched]: Linux timer freq = 250 (Hz), TimeBase freq = 2594248000 hz.
[ 946.374234] RTAI[sched]: timer setup = 999 ns, resched latency = 2943 ns.
[ 946.374285] RTAI[usi]: enabled.
[ 946.398774] RTAI[math]: loaded.
[ 946.440468] config string '0x378 out '
[ 947.446611] RTAI[math]: unloaded.
[ 947.467452] SCHED releases registered named ALIEN RTGLBH
[ 947.503609] RTAI[malloc]: unloaded.
[ 947.602241] RTAI[sched]: unloaded (forced hard/soft/hard transitions: traps 0, syscalls 0).
[ 947.603704] I-pipe: Domain RTAI unregistered.
[ 947.603743] RTAI[hal]: unmounted.

Hi John,

I have now rerun Step Conf, including the Pyvcp panel, I have verified in the various .ini files that the custom panel.xml is being called and the various pins are cross referenced as far as I can tell. I am not sure what the debug file information is trying to tell me but it still will not start.

Thank you for your help and sorry if this is really newby type problems - if there is a guide to get one from just installed to a running configuration that would be great as I then do not need to take up peoples' time with the basics.

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 - 2.5.1
Machine configuration directory is '/home/peet/linuxcnc/configs/BV20B-L'
Machine configuration file is 'BV20B-L.ini'
INIFILE=/home/peet/linuxcnc/configs/BV20B-L/BV20B-L.ini
PARAMETER_FILE=linuxcnc.var
TASK=milltask
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 TASK program: milltask
Starting DISPLAY program: axis
Shutting down and cleaning up LinuxCNC...
Killing task linuxcncsvr, PID=4128
Killing task milltask, PID=4183
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
custom_postgui.hal:20: signal 'spindle-at-speed' not found
4128
PID TTY STAT TIME COMMAND
4183
PID TTY STAT TIME COMMAND
Stopping realtime threads
Unloading hal components

Kernel message information:
[ 4777.657273] I-pipe: Domain RTAI registered.
[ 4777.657278] RTAI[hal]: <3.8.1> mounted over IPIPE-NOTHREADS 2.6-03.
[ 4777.657279] RTAI[hal]: compiled with gcc version 4.4.3 (Ubuntu 4.4.3-4ubuntu5) .
[ 4777.657307] RTAI[hal]: mounted (IPIPE-NOTHREADS, IMMEDIATE (INTERNAL IRQs DISPATCHED), ISOL_CPUS_MASK: 0).
[ 4777.657308] PIPELINE layers:
[ 4777.657310] fb4b5e20 9ac15d93 RTAI 200
[ 4777.657312] c085cb20 0 Linux 100
[ 4777.669170] RTAI[malloc]: global heap size = 2097152 bytes, <BSD>.
[ 4777.669268] RTAI[sched]: IMMEDIATE, MP, USER/KERNEL SPACE: <with RTAI OWN KTASKs>, kstacks pool size = 524288 bytes.
[ 4777.669272] RTAI[sched]: hard timer type/freq = APIC/6235800(Hz); default timing: periodic; linear timed lists.
[ 4777.669274] RTAI[sched]: Linux timer freq = 250 (Hz), TimeBase freq = 2594248000 hz.
[ 4777.669276] RTAI[sched]: timer setup = 999 ns, resched latency = 2943 ns.
[ 4777.669327] RTAI[usi]: enabled.
[ 4777.693267] RTAI[math]: loaded.
[ 4777.734634] config string '0x378 out '
[ 4778.764918] RTAI[math]: unloaded.
[ 4778.786334] SCHED releases registered named ALIEN RTGLBH
[ 4778.818206] RTAI[malloc]: unloaded.
[ 4778.917887] RTAI[sched]: unloaded (forced hard/soft/hard transitions: traps 0, syscalls 0).
[ 4778.919413] I-pipe: Domain RTAI unregistered.
[ 4778.919452] RTAI[hal]: unmounted.

Looks like the problem starts here...
custom_postgui.hal:20: signal 'spindle-at-speed' not found
Try commenting that line out and see if it loads.

Rick G

Thanks Rick.

I now have CNC running, just need to sort the hardware, then see if I need Spindle at speed!

Regards
Peet

Glad to hear you are up and running, of course John did all the heavy lifting!

Rick G

Thank you John!

This is exactly what I was hoping for. I have changed it and the program now loads with those lines uncommented.
I wonder if that could be a programming error in stepconf?, generating the file incorrectly.
I will create the file for my 3 axis dremel router I want to build, and see if it does the same.

I have created my dremel router and it is happy, not sure if I will use spindle speed on that one, but it works, so must be a lathe config error if it is one.

I have now started building an expansion board. When I disable E-stop I get the LED on - great 1st step! I then boldly switch machine on, expecting some more action, but instead I get "joint 0 on limit switch error", and "joint 2 on limit switch error". I used HAL scope to check signals, and I get true and false readings when I pull them low, so the input seems to be there. I am not getting a state change on spindle index, phase a & b, which is worrying as I can see they are working on the LED's mounted on my board.

I suspect I need more editing in config files, but what?

By the way The problem with the spindle-at-speed issue seems to be a bug, I need to copy those last lines every time I run stepconf, then paste them back afterwards, it always gets them wrong!
Here is a screen shot of my current issue: