I measured the voltages across the potentiometers on both my X2 and X3  
they are both Harbor Freight machines.  The X2 about 15 months old and 
the X3 about 6 months old.  The X2 had 12 volts on P1, varying 
proportional to increasing speed on P2 relative to P3.   The X3 had 7 
volts on P3,  varying proportional to increasing speed on P2 relative to 
P1.  So both look like they can be controlled by the VFD outputs of the 
Gecko G540.  Other output pins can be used to control the direction and 
power through relays.  I am thinking that I might use the power relay to 
also switch control from Manual to computer so I will want multiple 
contacts or multiple relays working in parallel.  This should not be 
high duty cycle so standard coil and contacts should work.  I think I 
will leave the power switch in series with the new power relay so it can 
be shutdown either place and the Manual switch must be engaged before 
the computer can control the machine.  I have never used solid state 
relays, they sound interesting for higher number of switching cycles, 
but that would be expensive to implement the cross switching, is it 
worth it.  I still need to research what I am going to do about estop.  
I need to see how it is currently wired on each machine. 

   Now for the feedback.  What do you recommend to feed back the speed?  
I  would think that multiple pulses per revolution would aid faster 
response.  However, a single pulse per revolution would also serve as a 
sync point for rigid tapping.  Is this similar in character to the 
recent discussion on threading?  Which way is better, or do I need 
both.?  If multiple pulses, do they need to be 50 percent duty cycle?   
I was thinking along the lines of an opto-interrupter reading cutouts on 
a disk attached to the spindle pulley.  I am looking to sync to speeds 
over a range roughly from 50 to 6000 rpm.

Thanks
Hubert

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