need help 5i25/7i76 setup for plasma

Thanks for reply. were looking that up right now. To add more to how I have it wired the cable I bought from Hyper therm has 6 wires in 3 insulated jackets. Pin 3 and 4 are for plasma start and I have pin 3 green wire connected to pin 5 on tb4 of the 7176 and pin 4 black wire connected to pin 6 on tb4. Pin 12 the red wire goes to a 24vdc terminal in my electrical box and pin 14 black wire goes to pin 9 in tb6 of 7176. Pin 5 the white wire goes to thcad card on the bottom right screw terminal and pin 6 the black wire goes to the upper right screw terminal of the thcad card.
I dont have any relays like yours. Im thinking that The relays must be in the plasma torch and I think that I am just sending a voltage via the 7176 to close and open relays. Correct me if Im wrong and have to do something else. thanks again.

You do not send any voltage from the 7I76 to close any relays, torch start is done with a contact closure.
Hypertherm pin 3 and 4 require a contact closure so the spindle enable pins should work since they
are effectively a contact closure when the spindle is on

You should be able to verify this by starting the torch by manually shorting these pins

You can also verify that the ENA+ and ENA- pins connect when the spindle is on with a ohmmeter across the pins (if the hypertherm is not connected) or a voltmeter across the pins if the Hypertherm is connected. The voltmeter should read about 18V when the spindle is off and about 1.5V if the spindle is on.
You can check the polarity of pins 3 and 4 by measuring them with a DVM (The plus pin goes to ENA+ and the - pin goes to ENA-)

The arc OK signal is a contact closure _from_ the hypertherm (closed when the arc is established) so you have it wired OK

Thanks PCW, we are shutting down here for the night but will do my best to confirm these things. thanks again.

Need help with firing the torch...Up to the point where we can do touch-off...All works ok...When starting an actual cutting pressing the start arrow, and setting voltage to 118v 45amp and enabling the THC check box, the machine starts it's probing routine, reaches the surface of material, trips the probe switch, comes back up to 0.150" to pierce height. I get message "arc fail"...We performed the test as per PCW directions, with the results that the torch fires properly when shorted pins 3 and 4...We have checked and verified that all wiring is correct. I am at a loss as to why it is not firing.
Any help is appreciated...

HAL file is as follow:

# ******************
# Core EMC/HAL Loads
# ******************
loadrt trivkins
loadrt [EMCMOT]EMCMOT servo_period_nsec=[EMCMOT]SERVO_PERIOD num_joints=[TRAJ]AXES
loadrt hostmot2
loadrt hm2_pci config="firmware=hm2/5i25 num_encoders=1 num_pwmgens=0 num_stepgens=5 sserial_port_0=00xx"
loadrt pid names=pid.x,pid.y,pid.z
loadrt thc
loadrt debounce cfg=4
loadrt estop_latch count=3

#############################
#---Functions and Threads---
#############################
addf thc servo-thread
addf hm2_5i25.0.read servo-thread
addf motion-command-handler servo-thread
addf motion-controller servo-thread
addf pid.x.do-pid-calcs servo-thread
addf pid.y.do-pid-calcs servo-thread
addf pid.z.do-pid-calcs servo-thread
addf estop-latch.0 servo-thread
addf estop-latch.1 servo-thread
addf hm2_5i25.0.write servo-thread
addf debounce.0 servo-thread

############################################
# Create signal for external estop loopback
############################################
net estop-loopout iocontrol.0.emc-enable-in <= estop-latch.0.ok-out
net estop-loopin iocontrol.0.user-enable-out => estop-latch.0.ok-in
net estop-reset iocontrol.0.user-request-enable => estop-latch.0.reset
net remote-estop-main estop-latch.0.fault-in <= hm2_5i25.0.7i76.0.0.input-02

#net estop-loopout iocontrol.1.emc-enable-in <= estop-latch.1.ok-out
#net estop-loopin iocontrol.0.user-enable-out => estop-latch.0.ok-in
#net estop-reset iocontrol.0.user-request-enable => estop-latch.0.reset
net remote-estop-south estop-latch.1.fault-in <= hm2_5i25.0.7i76.0.0.input-03

#net estop-loopout iocontrol.0.emc-enable-in <= estop-latch.0.ok-out
#net estop-loopin iocontrol.0.user-enable-out => estop-latch.0.ok-in
#net estop-reset iocontrol.0.user-request-enable => estop-latch.0.reset
net remote-estop-east estop-latch.2.fault-in <= hm2_5i25.0.7i76.0.0.input-04

# create a signal for the estop loopback
#net estop-loop iocontrol.0.user-enable-out => iocontrol.0.emc-enable-in

#*****************************
#---Home and Limit signals---
#*****************************
net all-home <= hm2_5i25.0.7i76.0.0.input-00-not

#******************
# --- DEBOUNCE ---
#******************
setp debounce.0.delay 10
net debounce-all-home debounce.0.0.in

#***********************
# X [0] Axis RIGHT MOTOR
#***********************
setp pid.x.Pgain [AXIS_0]P
setp pid.x.Igain [AXIS_0]I
setp pid.x.Dgain [AXIS_0]D
setp pid.x.bias [AXIS_0]BIAS
setp pid.x.FF0 [AXIS_0]FF0
setp pid.x.FF1 [AXIS_0]FF1
setp pid.x.FF2 [AXIS_0]FF2
setp pid.x.deadband [AXIS_0]DEADBAND
setp pid.x.maxoutput [AXIS_0]MAX_OUTPUT
setp pid.x.error-previous-target true
setp pid.x.maxerror .0005

net x-index-enable <=> pid.x.index-enable
net x-enable => pid.x.enable
net x-pos-cmd => pid.x.command
net x-vel-cmd => pid.x.command-deriv
net x-pos-fb => pid.x.feedback
net x-output => pid.x.output

####################
# timing parameters
####################
setp hm2_5i25.0.stepgen.00.dirsetup [AXIS_0]DIRSETUP
setp hm2_5i25.0.stepgen.00.dirhold [AXIS_0]DIRHOLD
setp hm2_5i25.0.stepgen.00.steplen [AXIS_0]STEPLEN
setp hm2_5i25.0.stepgen.00.stepspace [AXIS_0]STEPSPACE
setp hm2_5i25.0.stepgen.00.position-scale [AXIS_0]SCALE
setp hm2_5i25.0.stepgen.00.maxvel [AXIS_0]STEPGEN_MAXVEL
setp hm2_5i25.0.stepgen.00.maxaccel [AXIS_0]STEPGEN_MAXACCEL
setp hm2_5i25.0.stepgen.00.step_type 0
setp hm2_5i25.0.stepgen.00.control-type 0
###################################
# ---closedloop stepper signals--- added 10/18/17
###################################
net x-pos-cmd <= axis.0.motor-pos-cmd
net x-vel-cmd <= axis.0.joint-vel-cmd
net x-output <= hm2_5i25.0.stepgen.00.velocity-cmd
net x-pos-fb <= hm2_5i25.0.stepgen.00.position-fb
net x-pos-fb => axis.0.motor-pos-fb
net x-enable <= axis.0.amp-enable-out
net x-enable => hm2_5i25.0.stepgen.00.enable

####################
# timing parameters X2 [0] Axis LEFT MOTOR
####################
setp hm2_5i25.0.stepgen.03.dirsetup [AXIS_0]DIRSETUP
setp hm2_5i25.0.stepgen.03.dirhold [AXIS_0]DIRHOLD
setp hm2_5i25.0.stepgen.03.steplen [AXIS_0]STEPLEN
setp hm2_5i25.0.stepgen.03.stepspace [AXIS_0]STEPSPACE
setp hm2_5i25.0.stepgen.03.position-scale [AXIS_0]SCALE
setp hm2_5i25.0.stepgen.03.maxvel [AXIS_0]STEPGEN_MAXVEL
setp hm2_5i25.0.stepgen.03.maxaccel [AXIS_0]STEPGEN_MAXACCEL
setp hm2_5i25.0.stepgen.03.step_type 0
setp hm2_5i25.0.stepgen.03.control-type 0

net x2-pos-fb <= hm2_5i25.0.stepgen.03.position-fb
net x-pos-cmd axis.0.motor-pos-cmd => hm2_5i25.0.stepgen.00.position-cmd hm2_5i25.0.stepgen.03.position-cmd
net x-enable axis.0.amp-enable-out => hm2_5i25.0.stepgen.00.enable hm2_5i25.0.stepgen.03.enable
#************************************
# --- home / limit switch signals---
#************************************
net all-home => axis.0.home-sw-in
net x-neg-limit => axis.0.neg-lim-sw-in

#***********
# Y [1] Axis
#***********
####################
# axis enable chain
####################
newsig emcmot.01.enable bit
sets emcmot.01.enable FALSE
net emcmot.01.enable <= axis.1.amp-enable-out
net emcmot.01.enable => hm2_5i25.0.stepgen.01.enable

setp pid.y.Pgain [AXIS_1]P
setp pid.y.Igain [AXIS_1]I
setp pid.y.Dgain [AXIS_1]D
setp pid.y.bias [AXIS_1]BIAS
setp pid.y.FF0 [AXIS_1]FF0
setp pid.y.FF1 [AXIS_1]FF1
setp pid.y.FF2 [AXIS_1]FF2
setp pid.y.deadband [AXIS_1]DEADBAND
setp pid.y.maxoutput [AXIS_1]MAX_OUTPUT
setp pid.y.error-previous-target true
setp pid.y.maxerror .0005

net y-index-enable <=> pid.y.index-enable
net y-enable => pid.y.enable
net y-pos-cmd => pid.y.command
net y-vel-cmd => pid.y.command-deriv
net y-pos-fb => pid.y.feedback
net y-output => pid.y.output

##############################################
# position command and feedback
##############################################
net emcmot.01.pos-cmd <= axis.1.motor-pos-cmd
net emcmot.01.pos-cmd => hm2_5i25.0.stepgen.01.position-cmd
net motor.01.pos-fb <= hm2_5i25.0.stepgen.01.position-fb
net motor.01.pos-fb => axis.1.motor-pos-fb
####################
# timing parameters
####################
setp hm2_5i25.0.stepgen.01.dirsetup [AXIS_1]DIRSETUP
setp hm2_5i25.0.stepgen.01.dirhold [AXIS_1]DIRHOLD
setp hm2_5i25.0.stepgen.01.steplen [AXIS_1]STEPLEN
setp hm2_5i25.0.stepgen.01.stepspace [AXIS_1]STEPSPACE
setp hm2_5i25.0.stepgen.01.position-scale [AXIS_1]SCALE
setp hm2_5i25.0.stepgen.01.maxvel [AXIS_1]STEPGEN_MAXVEL
setp hm2_5i25.0.stepgen.01.maxaccel [AXIS_1]STEPGEN_MAXACCEL
setp hm2_5i25.0.stepgen.01.step_type 0
setp hm2_5i25.0.stepgen.01.control-type 0
#*****************************************
# ---setup home / limit switch signals---
#*****************************************
net all-home => axis.1.home-sw-in
net y-neg-limit => axis.1.neg-lim-sw-in

#***********
# Z [2] Axis
#***********
####################
# axis enable chain
####################
newsig emcmot.02.enable bit
sets emcmot.02.enable FALSE
net emcmot.02.enable <= axis.2.amp-enable-out
net emcmot.02.enable => hm2_5i25.0.stepgen.02.enable

setp pid.z.Pgain [AXIS_2]P
setp pid.z.Igain [AXIS_2]I
setp pid.z.Dgain [AXIS_2]D
setp pid.z.bias [AXIS_2]BIAS
setp pid.z.FF0 [AXIS_2]FF0
setp pid.z.FF1 [AXIS_2]FF1
setp pid.z.FF2 [AXIS_2]FF2
setp pid.z.deadband [AXIS_2]DEADBAND
setp pid.z.maxoutput [AXIS_2]MAX_OUTPUT
setp pid.z.error-previous-target true
setp pid.z.maxerror .0005

net z-index-enable <=> pid.z.index-enable
net z-enable => pid.z.enable
net z-pos-cmd => pid.z.command
net z-vel-cmd => pid.z.command-deriv
net z-pos-fb => pid.z.feedback
net z-output => pid.z.output

####################
# timing parameters
####################
setp hm2_5i25.0.stepgen.02.dirsetup [AXIS_2]DIRSETUP
setp hm2_5i25.0.stepgen.02.dirhold [AXIS_2]DIRHOLD
setp hm2_5i25.0.stepgen.02.steplen [AXIS_2]STEPLEN
setp hm2_5i25.0.stepgen.02.stepspace [AXIS_2]STEPSPACE
setp hm2_5i25.0.stepgen.02.position-scale [AXIS_2]SCALE
setp hm2_5i25.0.stepgen.02.maxvel [AXIS_2]STEPGEN_MAXVEL
setp hm2_5i25.0.stepgen.02.maxaccel [AXIS_2]STEPGEN_MAXACCEL
setp hm2_5i25.0.stepgen.02.step_type 0
setp hm2_5i25.0.stepgen.02.control-type 0
#*****************************************
# ---setup home / limit switch signals---
#*****************************************
net all-home => axis.2.home-sw-in
net z-neg-limit => axis.2.neg-lim-sw-in

##############################################
# Position command and feedback is Hijacked
# by the THC component...
##############################################
net emcmot.02.pos-cmd thc.z-pos-in <= axis.2.motor-pos-cmd
net thc-pos-cmd thc.z-pos-out => hm2_5i25.0.stepgen.02.position-cmd
net motor.02.pos-fb axis.2.motor-pos-fb <= thc.z-fb-out

#******************************
# connect miscellaneous signals
#******************************
# ---HALUI signals---
net machine-is-on halui.machine.is-on
net MDI-mode halui.mode.is-mdi

# ---jog button signals---
#sets jog-speed 200.00

##############################
#---Touchoff/Probe signals---
##############################
net torch-probe <= motion.probe-input <= hm2_5i25.0.7i76.0.0.input-01-not
net probe-in <= motion.digital-in-01 <= hm2_5i25.0.7i76.0.0.input-01
#net probe-in <= hm2_5i25.0.7i76.0.0.input-01

#******************
# --- DEBOUNCE ---
#******************
setp debounce.0.delay 100
net debounce-probe-in debounce.0.1.in

#******************
# reads the volts
# setting from the (added 1/28/2018)
# G code M68 E0 Q
#******************
#net volts-requested thc-pid.volts-requested <= hm2_5i25.0.7i76.0.0.motion.analog-out-00

####################################
# Set up the Encoder for use by THC
####################################
setp hm2_5i25.0.encoder.00.counter-mode 1
net thc-vel-in hm2_5i25.0.encoder.00.velocity => thc.encoder-vel
setp thc.scale-offset 118000
setp thc.vel-scale 0.00037866834
#**************************************
#---this might need to be increased---
#**************************************
setp thc.correction-vel 0.0005

###############################
# spindle on starts the arc
###############################
net spindle-on motion.spindle-on => hm2_5i25.0.7i76.0.0.output-06
net spindle-on thc.torch-on

####################################
# starts the motion when the plasma
# arc has transfered to the work
####################################
net start-motion-input thc.arc-ok <= motion.digital-in-00 <= hm2_5i25.0.7i76.0.0.input-08

#************************
# --- Estop Power ON ---
#************************
#net estop-out hm2_5i25.0.7i76.0.0.output-07

###########################################
# Create signals for tool loading loopback
###########################################
net tool-prep-loop iocontrol.0.tool-prepare => iocontrol.0.tool-prepared
net tool-change-loop iocontrol.0.tool-change => iocontrol.0.tool-changed

I think you need
Nothing moves until the spindle is at speed so this fudges it to be at speed all the time

Most probably you have to add Sxxx after M3 in gcode, where xxx is any number except 0.