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Hi Guys,

A plasma machine I built that runs the original PlasmaC is having a fatal error message that is stopping the machine from operating. 

   

The guys who run the machine tell me the machine ran fine last Friday and when they came to use it on Monday morning they got this error message not matter what gcode program they tried to run.

This same issue happened back in March, and the only way I could fix the issue was to reformat the machine to a default state. Since it is re-occuring, there must be something going on to cause the issue.

Ive attached the gcode file to this post. 

I finally got around to getting everything wired up enough to test.
At first, I couldn't get it to start using a relay and a power supply on a switch. I realized the manual says "or dry contact closer", so I wired the relay directly to start- pin 15 and start+ pin 34, which worked.

Now I can't get my arc ok signal. I followed the example wiring in the manual. I connected ark ok+ pin 23 to the relay. Then 24vdc+ pin 37 to the relay. Then ark ok- pin 4 to power ground pin 36.
Wired up like this, the arc will not start and the plasma cutter gives an error. If I disconnect the ground to ark ok- pin 4, the plasma will start without errors. I am getting 24 volts between power and ground, and the 2 ark ok pins will close the circuit when the arc starts.

I am attaching the examples from the manual plus diagram of how I wired the arc ok relay.
I may have wired it up like example 4(which it says don't use) a long time ago before I decided to remove the old interface connection on it, so maybe that messed it up.

Does my ark ok wiring seem right? Should I try wiring it differently or should I consider using a reed relay instead?
 

Poke. Figured I should stick this here.

Machine is back together with some new upgraded, ethercat is working for the xyz.

Now I'm on to making the spindle work with modbus.
Is there a simple step by step instruction to set this up? I got a usb adapter, and I'm running qtdragon. In addition to just tuning on and off, id like it to display the true spindle speed and the load.

Thanks