how to setup a Mesa 7i80HD?

Could you please define "better"?

First you explained, that bringing the stepper encoders to linuxcnc is not very useful, as the stepper driver needs the encoders. Ok, I understand that point.
So the only remaining encoders are manual encoders for manual movement oder speed limitations - so no special speed requirements.
The 7i47S offers a spindle interface (direction and PWM-Speed), which the 7i52S does not.
I need a spindle interface.

So where and why is a 7i52S better for my requirements as a 7i47S?

... and why noone mentioned the pin-configuration of the mesacards?
Is it possible?
And if so, how can I resolve an individual setting?

The 7i76 ticks a lot of boxes in 1 card but you are short 1 stepgen and 1 MPG encoder. But there are examples in the docs of using 1 MPG input for multiple Axes if you can live with an axis selector switch for your MPG's. That would let you get by by by just adding a 7i78 DB25 daughter card for the remaining stepgen. The RS422 pendant interface might also be an option if you must have separate MPG encoders. Not sure if there is a bit file though.

andypugh wrote:

..., but that might not be the most convenient time to find out.

LOL - yes sir

I'd like to know it before I waste my money.
I'm willing to follow your recommendations, but I stil don't have the picture.
_

andypugh wrote:

The definitive way to find the pin layout of a firmware is to look at the .pin file (where it exists) or the .vhd file that the firmware is created from.

When I look at the archives from mesa, there're no .pin files.
The .vhd files are there, but no Makefile to build a certain .bit-file, which I assume is the firmware to load to the FPGA.
_

rodw wrote:

The 7i76 ticks a lot of boxes in 1 card but you are short 1 stepgen and 1 MPG encoder. But there are examples in the docs of using 1 MPG input for multiple Axes if you can live with an axis selector switch for your MPG's.

No I can't live with an axis selector switch.
I start with a 4-axis gantry mill, which means 5 step/dir channels, 5 endstops, a spindle channel, about 3 encoders and about 5 relais. The endstops will be switched, depending on the 4th axis.
The fifth axis and a toolchanger are already planned, so to be precise, I'd need 7 channels.
May be I can use a switch for the 5th axis and the tool changer, but before, I have no axis to switch.

I have no problem, create a daughterboard on my own with RS422 transceivers, but I have no idea, how to configure the pin settings of the mesa card to suit my needs.

So where and why is a 7i52S better for my requirements as a 7i47S?

Because on your original request you wanted 6 step/dir outputs and 6 encoder inputs
you cannot do this with a 7I47S

(a 7I47S would have 4 step/dir outputs max + 4 full encoders or possibly 6 encoders
with a strange pinout by dropping the index pins)

Your specs seem to have grown. 7i76e with a 7i76 daughter card will give 10 stepgens, 2 spindles with encoders and 4 x MPG. The relays and other IO have never been a limitation but you'll probably find you want to run separate min, max and home switches on every stepper joint. But even 1 x 7i76e will probably have enough I/0.
EDIT: But I think what I suggested earlier will work out cheaper...

andypugh wrote:

So, as an example the file 7i80hd_16_svst6_6_7i52sd.bit will have been made using the .vhd file PIN_SVST6_6_7I52S_72.vhd

GREAT! Thanks!
Looks like the pin-definition can be changed without learning vhd
Can I use each pin-definition at any pin, or exists pins with special meaning?
Do I have to change "ModuleID" when I change "PinDesc"?
Where can I find the naming rules for filenames?
... and when I created my own pin-file, how do I generate a .bit-file?
_

andypugh wrote:

For extra MPG channels ...

what is a MPG channel?
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andypugh wrote:

the 7i73 is a pretty good solution for a control panel

yes, that card looks very interesting! Thanks!
Where can I find a pin-definition for connecting to 7i73?
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andypugh wrote:

See "SOFTWARE PROCESS DATA MODES"

as far as I know, I don't have analog input channels.
The pwm-channel for spindle speed - is it analog output or is it regular I/O?
I have step/dir, pwm, encoder and digital I/O - will mode 0 be appropriate?
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PCW wrote:

Reinhard wrote:

So where and why is a 7i52S better for my requirements as a 7i47S?

Because on your original request you wanted 6 step/dir outputs and 6 encoder inputs
you cannot do this with a 7I47S

Ok, but it was your recommendation, not to bring the encoders to linuxcnc.
If there's a reason stil bringing the encoders to linuxcnc, please tell me.
_

rodw wrote:

Your specs seem to have grown.

Not really. Look at my second post.

but with the possibility of generating my own bit-file, I can now figure out my setup and decide, whether a 7i92 will suffice or whether I need a 7i80HD
Very nice!

cheers

after playing with the needed channels, it looks to me, that the 7i92 is to small for my requirements.
So a 7i80HD + 7i52S seems to be a good starting point. 6 step/dir channels and 3 MPG looks fine. I guess, digital I/O will work without any daughterboard. So this tuple looks nice but is lacking support for spindle control.
How can I add support for spindle speed?
7i80HD could drive 3 daughterboards, right?

The 7i73 looks really nice. I would like to go for one too. But how do I connect such a card to ... what? PC? or 7i80HD?
... and if I use multiple daughterboards, I'll have to create my own .bit files too - right?

I found two .bit files for the 7i80+7i52S: 7i80hd_16_svst6_6_7i52s.bit and 7i80hd_16_svst6_6_7i52sd.bit
What's the difference between them?
When I compare the PIN* files, some PLL registers apear in one, but no difference at pin configuration.

Is the xilinx design suite the only way to generate a .bit file?
I have to rip off my cloths for registration, abuse internet for huge download and flood my harddisk with unwanted software ...
... what a mess!