Configuration 7i92_g540_85sd

Back in May I requested and received a .bit file for the 7i92 with a G540 pinout for P2 and a 7i85 for P1. I finally got some shop time and believe the 7i92_g540_85si I requested is also now in the 7i92.zip. Big picture was using Mesa cards so I can add linear encoders to my lathe and mill.

I went through pncconf using the 7i92_G540x2D thinking P2 would be defined the same. I have my steppers working, but my spindle encoder (A/B/Index) running through the G540 pins doesn't work. 7i92_g540_85si has the pins I need for my encoder mapped to general IOPorts.

IO Connections for P2 (7i92_g540_85si)
Pin# I/O Pri. func Sec. func Chan Pin func Pin Dir
10 13 IOPort None
11 14 IOPort None
12 15 IOPort None

IO Connections for P2 (7i92_G540x2D)
10 13 IOPort QCount 0 Quad-A (In)
11 14 IOPort QCount 0 Quad-B (In)
12 15 IOPort QCount 0 Quad-IDX (In)

Once I get my current functionality working, I will add some linear scales to the 7i85. I am trying to stick with the existing wiring.

Question 1) Is there a way using .hal to map the P2 pins to a mesa encoder? The spindle encoder is only a 120/rev so I guess I could use a software encoder with the IOPorts. It worked before but I thought it would be nice to use the mesa hardware for this.

Question 2) Or do I need to get a new .bin with an encoder assigned to the G540 P2 connector? This would match the G540x2D P2 pins and allow me use PNCConf to configure P2. I would still need to tackle the new linear encoders on P1.

Last option is to break my existing working PP configuration and rewire the spindle encoder to the 7i85 encoder inputs.

I think I dropped the encoder on the G540 because the G540 inputs are too slow
for most encoder signals. Here's a bitfile with the encoder (#4) on P2:

Thanks!
The low resolution spindle encoder currently wired up works fine through the G540. The linear scales will go into the 7i85.

I am still having problems with the mesa board using the spindle signals from my G540. The original configuration had PP pins 10,11,12 set as IOPorts which should work using a software encoder. But when I use the G540 connected to the 7i92 and use HalMeter and check hm2_7i92_0.gpio.013.in to check PP pin 10 I do not see a logic change when I ground the input going into the G540. Same for PP 11,12 and gpio 14,15.

If I run a parallel port configuration with the same G540 and encoder wiring, I can ground the inputs and see the expected change using HalMeter par pins 10,11,12

I also tried the 7i92_g540_7i85sd.bit file which defines these pins as a chan 2 encoder. When I look at the encoder.02.input-a or the gpio pin it doesn't change when I ground the G540 input. (If I ground the 7i85s encoder 0 input at the terminal block, I see the expected logic changes)

I checked the 7i92 P2 pin 10,11,12 solder points with a DVM and I see the voltage level change from 2.3V to 4.4V when the corresponding G540 input is grounded. But HalMeter doesn't show a change in the mesa gpio or encoder pins. Are these voltages in range for the 7i92? W1 is in the default 5V position.

That's odd, that means the G540 output will not swing to ground with
the 4.7K pullups on the 7I92 input pins. The 7I92 expects TTL level
input signals (lower than 0.8V for a low level and greater than 2.4V
for a high level)

Is W4 down? (it must be for a G540)

You could verify that there is no electrical issue by grounding
DB25 pins 10,11,12 via a DVM set in the mA current range,
you should get about 1mA (5V/4.7K) (test with G540 unplugged)