Spindle and encoder

The spindle is a brush motor, 115 VAC, 60 Hz, Single Phase to a rectifier and speed control, 90 VDC (60 Hz), start current 1.7 amp, full load current 0.85 amps and maximum 6100 RPM.  Motor to spindle pulley ratio 0.46 and maximum 2800 RPM.  Masso single-ended incremental encoder with channels A, B and Z and maximum 60kHz.  Pulley 10 pulses per revolution (lines per revolution) and 1 index.

7i96s card
Terminal Block 2
Voltages from multi-meter
PIN 24 Spindle+ and PIN 22 Spindle- or PIN 23 Spindle Out at 7.38VDC when spindle-off (M5). 
MDI, G97 S250 M3 but tachometer 23 RPM.

MDI, G97 S1000 M3 but tachometer 370 RPM, Spindle+ & Spindle Out 2.4VDC, and Spindle+ & Spindle- 2.85VDC. 
A+ 3.3VDC, B+ 3.3VDC & Z+ 6.4VDC.

MDI, G97 S3000 M3 but tachometer 2312 RPM.

MDI, G97 S250 M3 is about the lowest commanded RPM the control accepts yet to rotate the spindle.

PncConf Wizard
Meso Card 0
7i96s
7i96s_d
I set 'Num of channel 3' and tried 'Accept component changes' but 'Num of channel' defaults to 1.  Should it be 3 channels if the encoder is A, B and Z?

Does the Spindle Motor page not have enough specifications to calibrate the spindle motor and encoder, positioning and or indexing, constant surface feet and accurate RPM and GUI feedback?

LinuxCNC_Documentation.pdf (LinuxCNC V2.8.4-23-g93a844ef5, 2022-12-01) 

Page 678
12.2.2 PWM Spindle Speed
12.2.6.1 Spindle Synchronized Motion
I'm considering these configurations but not using a parallel port.  

7i96s card particular
Terminal block 2 
PIN Signal
22  Spindle-
23  Spindle Out
24  Spindle+ 
7   EncA+ 
10  EncB+
13  IDX+ (channel Z)  

Are 12.2.2 and 12.2.6.1 configurations required in addition to the .hal file the PncConf generated and to calibrate the spindle motor and encoder, positioning and or indexing, constant surface feet and accurate RPM and GUI feedback?  Do any PINs need to be edited to match the 7i96s?  Does PWM Spindle Speed and Spindle Synchronized Motion get inserted at the top of the .hal page underneath the other loadrt?  Do any additional specifications need to be inserted in the .ini file to configure the spindle?

Does the encoder work? That is, does the spindle position increase
or decrease by 1 each turn of the spindle?

Yes, the encoder works as much to my awareness. The encoder inputs signals to the 7i96s, EncA+ 3.3VDC, EncB+ 3.3VDC and IDX+ 6.4VDC. The encoder A, B, and Z LED's are blinking every line count. Does LinuxCNC have a file and where that'd show the encoder line counts when rotating the spindle?

Yes you would look at:

hm2_7i96s.0.encoder.00.position

with either halshow or halmeter

You can launch either from Axis's "Machine" pull down menu

(you launch halshow with "Show Hal Configuration")

The halmeter hm2_7i96s.0.encoder.00.input-index alternates True/False.  The halmeter hm2_7i96s.0.encoder.00.position twitches less or greater some manual rotations (graduations) but gradually the greater and some other manual rotations just increase 1.  How is the spindle configuration file updated?  Should the 12.2.2 PWM Spindle Speed and the 12.2.6.1 Spindle Synchronized Motion be used?  I'd like the programmable spindle accurate about a few RPM read with a tachometer.  

The 'voltage dividers' remind me of voltage regulators. The control box does include a voltage regulator to reduce the voltage from the main power supply. The voltage regulator pot is set to 13VDC output to the encoder. The encoder accepts input 12VDC-24VDC (docs.masso.com.au/wiring-and-setup/setup...asso-optical-encoder). Varying input voltage within range doesn't seem to change the output voltage of the encoder. The encoder is single-ended and uses TTL signals. The 7i96s jumpers W1, W2 and W3 are set to the left. Could the Masso encoder Z channel be designed to output approximately 6.4V? The encoder input 13VDC may not be adjustable on the card and distributed (divisible) voltage permanence. Can a 'voltage divider' or regulator (module or card) be used in line with the Z channel and TTL input and maintain the TTL signal? Is okay if the 7i96s IDX+ receives an additional 1.4VDC and will maintain a TTL signal?

Masso Optical Encoder terminal block.

Spindle about 250 RPM.
-ve, Ground
+ve, 12.96VDC power supply
Output Signal Z 8.25VDC
Output Signal B 5.34VDC
Output Signal A 5.14VDC

Spindle-off, manually rotate the pulley until the line intersects the channel and is lit.
-ve, Ground
+ve, 12.95VDC power supply
Output Signal Z 9.5VDC
Output Signal B 9.49VDC
Output Signal A 9.52VDC

I guess I could disable channel Z if it were to cause an interface with the 7i96s. However, I'd like to use it if available with a combination of channels A and B. I could probably use a different encoder as an alternative but rather not if not necessary.

Do you have the specifications of the Masso encoder?

Note that the A/B/Idx inputs on the 7I96S must swing close to ground
(Ideally less than 1V in the low state) to be recognized by the 7I96S