Retrofitting an 89 Chiron FZ12W aka Igor

For two of my three retrofits I ordered them in the US and had them shipped over. Worked well.

As you can see, they don't have 7i77 and 7i92H, the closest alternative is 7i97 and 7iA0, but I have a much smaller number of outputs.
Perhaps the only way to combine the outputs from this I/O card and then to the relays is to get a larger number of available outputs.
or maybe you have a better combination, although yours is much better because if the analog DC drivers and motors fail, then
I just replace the analog 7i77 with one of the digital ones and the DC drivers and motors with AC.

the 7i97 with the other cards should have enough IO's of your machine.
I would start by making me a List of all the IO's on the machine which are in use what addition IO's I will add later and then chose the suiting card combination. I have plenty in spare on the Chiron. With the latest cards I my have opted for another setup.

Okk

My I/O scenario.....

Hi Is your Spinde really Really run by IO's Mine runs with +-10V
and have just one controller release.
have you checked with the wiring?
Watt about the controller releases for x y and z? are there none?
Same for Estop out?
Mine works with bi stable air valves. So I have one relay for spindle up and another for down.
and a relay for all tools up. You should check that.

But still then you should be fine with one 7i97 and one 7I84

You are right, I just saw in the documentation that it is the same as your spindle at +/- 10V also for the spindle up and down via two relays as yours.
As for releasing the axes, I can't figure it out...but as far as I remember when it was working properly I had to release the e-stop after starting the machine in order to start the control and axes.
Today I am ordering 7i97 and 7I84, so we will be in touch when they arrive.

Best regards