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Does the machine have a floating head with switch?
Use that, skip ohmic for now, make the machine works properly first without it.
I never use ohmic probing, floating head only. To much trouble for not much gain, and my machines are used by clients, so as simple as possible for daily use.
Rod and others have made huge improvements to ohmic probing as it was useless before due to water ingress inside the torch, so i am thinking of adding it to one of my machines for quite some time, just need time.

Yes It has floating head. I used to have ohmic using two relays and it seemed to run ok with some intermittent issues. Somehow the retaining cap split at the threads and caused it to signal constantly.
I have a lot to still learn between hardware and linuxcnc so I might wire it in but leave it unused. This will make the 4th panel I have built previous boards were for Mach4 ESS/MB3.
Im hoping to have this panel finished out today, but thats what ive been saying for over a week

Just a friendly warning, USB extensions usually work ok if the cable is good and shielded, HDMI will most probably not work due to interference from plasma pilot arc, but do give it a try if you can, before splurging for a larger monitor.
I have a video of plasma causing the screen to go blank in the other shop, from the shop with full metal cladding about 8 meters away, using a crappy 28 Euro display port cable. So price is not the deciding factor of cable quality, i have much chepaer cables that have no such issues. Lately i only buy Baseus, Anker, or Ugreen cables, so far no disappointment.
As for Mach4, i feel sorry for what you had to go through, from reading on the net it was worse than 3, by a lot.
Welcome to the dark side, once you get LinuxCNC running, you never go back. Having machines running for 15 years without a single issue, ever, is so calming...

Thanks for the heads up, I have seen those issues on a Wright CNC table running Mach3 super annoying. For the extensions I did not think to see if they are shielded or not guess ill go look it up.
I do have a 32 inch LCD that on occasion I throw the screen up to when I'm not babysitting the table and haven't had an issue on that one.
I Should upload images of the current setup table and old electronics.for This Build I'm using end crimps and heat shrink on all the wires and trying to reduce the number of cables that run through the cable carriers.

FlaredFins wrote:

I do have a 32 inch LCD that on occasion I throw the screen up to when I'm not babysitting the table and haven't had an issue on that one.

This
www.youtube.com/shorts/P2xzqh3M9Rc

There is a diagram in the Plasma Primer document.
Its not wise to apply 24 volts to the 5 volt logic side. It will be costly!

For file transfers, a short USB extension will be fine. There are some nice  IP67 industrial connectors with dustcaps. Not so sure about HDMI as it implies a long term connection.
Personally, I would add a Wifi dongle with external antenna and transfer files to Linuxcnc via the network.

Yes Saw it shortly after my post this morning. Ive got it wired up just dont have the 24v going to it yet. I do have a few questions concerning the Ohmic Hypersensing post. How much of that still applies to the THCad2. I thought I read its the same card only difference is in which position W1 is in.
Also in the 7i96s does W1, W2, W3 need to be changed for height sensing and OHMIC?
Most of my build is finished so Ill be moving into the software to install some of the files I downloaded the other day and try to get it all configured.

Oh! almost forgot a link from here is the THCAD Calibration Setting Calculator For PlasmaC. it only list 10 and 300 to get the correct numbers will it still work for the THCad2?

Forget calculators. We let hal do the calculations.
I've attached a later version with a seperate hal file you can add to your ini.
This requires an additional resisotor if on a water table. I can't share that as I don't have access to Google Drive from here.

Set the thcad2 to use a 5 volt range and it is all still applicable.

I still want to get wifi and bluetooth working in 6.1 Kernel they work in 6.6 kernel but not sure if ill run into latency issues like i did in 6.5kernel. But yes when I have wifi working the reception is cut in half when the cabinet door is closed.

Get something like netplus.com.au/products/usb-wifi-adapter...ith-external-antenna
and a SM4 bulkhead cable (get the connectors right). Then you can relocate the antenna to the exterior. DOne this a few times now.

I think I saw the drawing for the resistor in the Plasma primer but Ive seen two versions of it with different resistors in place.

Found one on amazon. Just did my last cuts in Mach4 did 104 circles for a customer. time to tear down this table and start installing the new parts and hopefully fire up Linuxcnc next week sometime.

I finally got the enclosure finished and all wired in to use the THCad2 as my height controller. as you can see in the images, I've attached I installed a DC volt meter to measure the output voltage for the 50:1 divider from the hypertherm. My reasoning for this is just past experience in using a faulty Price CNC height controller in Mach 4. I was able to determine the read out on the Price was faulty and doing bad math as the voltage coming out of the hypertherm was the correct cut voltage. 

So my question is in attaching the volt meter in the manner I did am I creating any risk as in the possibility of reducing the voltage out or rather just the output (pulses) I cant remember how it out puts the info for the voltage for the THCad2 I dont think in doing this will damage the THCad2 but Im not 100% in that thought so I thought I would ask the people who are a little more versed in this board.