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You will likely need to  either merge some parts from a standard step/dir hal/ini file setup,
or use either pncconf's discovery option or MesaCT to create a working 7I77 + step/dir setup.

Hello again,

While checking availability, I noticed that in terms of cost and stock it might be more convenient to go with the 6i24, since it is currently available directly from Mesa USA. Otherwise, I would need to buy everything from Eurosurplus, which ends up being more expensive overall.

Could someone please confirm the main differences between the 6i25 and the 6i24? From what I see, the 6i24 has no limitations on its connectors, so in the future I could also leave an extra port available to add another servo control board if needed.

Thanks a lot for your help!

It is possible to use LinuxCNC to run cartesian (ie xyz) gcode on an industrial robot. However, since the planner has no information about the kinematics used and 'assumes' a cartesian joint/axes configuration you will not get uniform velocities over the robot's work space.
If accurate path velocities are important for your application then you are going to have a hard time using LinuxCNC with a manipulator.

Daan96 wrote:

Are the following components suitable for making a voltage divider? My plasma has a 1:1 arc output.
 

Yes.

Daan96 wrote:

I'm using a TH-CAD2 in combination with two resistors in series and a 0.1uF capacitor to absorb the voltage spikes. Am I doing this correctly?
 

Yes, but wire one resistor to each side of the arc voltage, not both on the same wire. That makes it much safer in case the cable is kicked somewhere on the way to electronics and lowers the interference caused by plasma source.
And you can skip the capacitor as it does work without it, but i like to have it as it smooths the voltage readout and subsequently the torch motion up/down while cutting, but it will limit a bit the reaction speed.

Daan96 wrote:

What happens if a voltage spike does occur? Will the capacitor fail?
 

Usually nothing, if the polarity is correct.

Daan96 wrote:

Can I connect the start arc and arc OK signals directly to the Mesa board, or is it better to use a relay to protect the mesa board?
 

Yes you can, 7i96S has two fully isolated outputs ( 4 and 5 i think, double check that), so no need for relay.

Daan96 wrote:

Can I route these signals to the plasma cutter through the same cable as the THC?
 

Yes, if the resistors are mounted inside or outside the plasma source, but close to the plasma source.