5i25/7i76 analog spindle control on Lathe spindle

My spindle motor is a 90v dc treadmill motor, I am using a Cyclotrol C150 controller (0-10V analog) (potentiometer replacement).
The motor will supposedly run 3200rpm at 110v. I have it geared down to the spindle 20 teeth on the motor and 45 teeth on the spindle.
I have a 100 slot counter with index on the Spindle. Should I ignore the gearing and just treat it as a 1100 rpm motor at 10v.
Then calculate the scaling from that or how should I deal with the scaling. Currently the at-speed indicator works up to about 100rpm and then turns off for higher speeds.

the following is from PNCConf:
net spindle-vel-cmd-rps    =>  near.0.in1
net spindle-vel-fb-rps         =>  near.0.in2
net spindle-at-speed       <=  near.0.out
setp near.0.scale 1.000000
setp near.0.difference 8.333333

 

Does sound like the scaling is off

You probably need to check the actual vs commanded RPM
over the entire range to figure out the proper scaling number
 

spindle-vel-cmd-rps is positive but spindle-vel-fb-rps is negative.
Should I use spindle-vel-fb-rps-abs???
So it seems that the comparison is destined to fail at the moment,
there is some (significant) difference in the value of the commanded vs reported speed.
If I can get it compare positive to positive maybe I can figure out the correct scale.

At minimum, you need to change the sign of the encoder scale
 

What is the line
setp near.0.difference 8.33333
supposed to do?

After changing the ENCODER scale, I have At-Speed indicator all the way up to 1000-1100 rpm. I looked up the motor and it is rated at 3200 rpm at 110 volts. It looks like I am getting a max of around 2475 rpm.

setp near.0.difference 8.33333

In this case means you have to be within 8.33 RPM of the
commanded RPM to make spindle at speed true

man near
 

I turned on the spindle in Axis and bumped the speeds using the "+" button.
Here are the RPM outputs for CMD vs FB using HALSHOW:
CMD   0   101   201   301   401   501
FB       0  180   390   600   800 1000

FB is an approximation because it was fluctuating over a range of about 20rpm.
Spindle basically maxs out at 500rpm commanded.

So is the encoder scaling wrong? (2x too high)

Is there an independent way to measure the actual spindle RPM?

I can't think of anything that I have that would allow me to do that.
I edited the first message to add my ".hal" and ".ini" files.

One thing that seemed weird to me was in pncconf. Even though I had single input 100 line encoder checked, if I go into "calculate scale" it shows 25 line encoder x 4.

Did you verify that you get 100 counts if you rotate the spindle one turn by hand?

Is the scale in the INI file 100? (or -100)