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I think I have the system in control now, and have reached the point where I want to add an encoder to the spindle for rigid tapping and better speed control.
My plan had been to add a toothed wheel with a pair of hall effect sensors, one a few teeth away, but half a cycle out of phase for quadrature, and a third for an index. Then connect these directly into the 7i77 channel 5 encoder inputs. (some biasing resistors maybe required also)
The maximum spindle rpm is 3500. I was proposing 40 teeth, but on say an M6 thread with 1mm pitch, I think that's a possible pitch error of .00625mm, which is pretty small, but I guess 100 would be better. I'd appreciate others opinions on this choice please.
Secondly, because of the belt run and lack of clearance around the belt pulley, putting the index tooth on is a much bigger mission than I was expecting.
Can I simply delete it and use a missing tooth, or pair of missing teeth as the index?
What looks to me like it might not so simply work is the encoder quadrature when it reaches the missing tooth, or am I over thinking this?
Thanks

Maybe lcec doesn't find the device or it doesn't go to OP.
From "ethercat slaves", are they in OP?
In halshow, can you see the pin lcec.0.0.statusword?
Any clues from "sudo dmesg", the last say 50 lines are of interest.

Edit. I looked a bit closer at the ethercat-conf.xml file.
You have double info, which I haven't seen before. Where does the info in that file come from?
I am not used to see a lot of PDOs in syncManager 0 and 1, but always have the PDOs
in SM 2 and SM 3. And you have the info there as well.

Can you test to replace the contents in ethercat-conf.xml of the clients with this

github.com/LinuxCNC/linuxcnc/pull/2722

Seems like a better solution if possible.

How adventurous do you feel?

github.com/LinuxCNC/linuxcnc/pull/2722

you need to execute 'lcnc_logger.py' with linuxcnc running. This can also be done using a custom mcode as outlined here (note that the file has since been renamed to 'lcnc_logger.py') :
forum.linuxcnc.org/21-axis/30986-axis-po...gger?start=60#294514

I can make a configuration with UARTs but there is no direct hal support
for communication between two systems.

What other I/O do you need on the 7I94Ts?

How much data needs to be exchanged?

i get command not found on many of the commands from the text tutorial

Tomorrow I would like to get the 2 7i94ts to connect using a mesa uart connection. Not sure which firmware to flash. Had a look through the available ones but there isn't an obvious choice. 

PCW, is there one available, if so which one?

Thanks
Henk

Yes, in most cases, mesaflash is not needed as the installed firmware is sufficient.
 

Yes. Current stable version 2.9.4 ISO
I think that mesa and linuxcnc card experts may not have even noticed this. because they either knew where and how to download the updates without a problem. or they skipped this step altogether and did the configuration right away.

how to run lcnc_logger? what to add in .ini file?

Thanks for the reply but I believe I made all those changes and it made no difference, did I do it wrong or is the problem something else?

The HAW show shows that automatic tuning is not enabled.
What can I test? The problem I have is serious.

Changed topic title to something a little more verbose.

Yes, a fairly ancient version of mesaflash (3.4.9)  is included with the
LinuxCNC 2.9.4 ISO, this is supposedly fixed for later releases.