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This installation is on master-rtpreempt although it could be far behind as I cannot get to connect to the repository.

I have changed this installation to the latest 2.9.2 now so we can go test it later today.
I will let you know if it changed anything

If you still have issues can you post the config backup created from the settings tab. 
 

Phill
I upgraded the system to the latest master but still will not enable the THC. The THC Enable button is on but the enabled LED never comes on

Could you try it with Auto Activate in the THC frame of the PARAMETERS tab unchecked.

Phill it remains off. That enabled LED never comes on even if we run a Gcode with THC enabled as well.

I have my machine running and everything with it seems to be running well. The one problem I have is the tips on the torch keep getting ruined and then the plasma arc seems to come out at different angles. I had thought maybe it was water in the air lines but I'm pretty confident that I have dried the air and it still happens. A 10 minute cut with a couple dozen pierces and I need to replace the cup. When the tip is new it cuts very straight and cleanly.

I have a 1.2 tip in the everlast 82i with it set to 45 amps and 80 IPM for 10 gauge steel. I have tried increasing the voltage more to the max rating for the tip but that didn't seem to change anything. I run the torch around .06 off the material with it on auto volts and it seems to keep that height pretty well with the THC. Wondering what I should focus on to get it tuned in. Is there anything out there in the way of a tuning guide for the THCAD? Thanks for any help.

Raise the "pierce height" up to where it starts misfiring, then lower a mm or two.

Waited 7 days to boot the spammer, and today came back adding more posts and links.

I would say water. I had to ad da refrigerated air drier and it fixed everything.

Is that with Auto Activate both checked and unchecked.

Did you confirm that the VEL: reached the same as FR: during the cut.
 
 

I will have to confirm that but I thought it did. He just let me know now that the THC Enabled LED did come on with Auto Active unchecked. The customer has left the shop for on-site work but I will check when he gets back in to see about the velocity.

I have just had a look at the ini file and there are some settings that require changing.
The three [AXIS] values need to be double the value of the corresponding [JOINT] section.
The new values should be something like below: 

phillc54 wrote:

Is that with Auto Activate both checked and unchecked.

Did you confirm that the VEL: reached the same as FR: during the cut.
 

 
I cannot do this as the machine does not display the material information even if it is selected on the settings page. My own installation has the same problem. I cannot see the material file information either. On my sim I can see it. Bothe machines are running master. One on bookworm and the other on Buster.

 

So I can confirm that the vel reaches the required feed rate.