Mesa 7i96s Torch on and arc ok problems?

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07 Nov 2025 17:58 #338040 by Boltten
Hi everyone,I’m finishing up my CNC plasma build using a Mesa 7i96s, Spartus ProCut 45PCF, and a THCAD-5 (not yet connected).My issue:
The torch on output (OUT0) from the Mesa won’t trigger the plasma directly.
If I short pin 3 & 4 on the Spartus CNC port manually, the torch fires instantly.
When I run the signal through a relay, it also works fine.
But when I connect the Spartus directly to OUT0+ and OUT0-, (or OUT5) nothing happens — even though the Mesa output LED lights up and I can measure switching.The Arc OK behaves similarly — it only works through a relay. But when i have torch pulse on it stays active. And when cutting a circle is just flashes real quick and torch dies. 
The output LEDs on the Mesa board are about half as bright as the input LEDs.All 0 V lines in my control cabinet go to a common terminal, which is also tied to PE (earth) and the machine frame.
I have 24 V on IN COMMON, and everything else seems correct.Has anyone successfully triggered a Spartus ProCut 45PCF directly from a Mesa 7i96s output (without a relay)?
If so, could you share how you wired OUT0+ / OUT0- relative to the plasma CNC port pins (3–4)?I’ve looked through other wiring diagrams and posts, but haven’t found a clear answer yet.
Any suggestions or example diagrams would be very much appreciated. I will try and make a diagram of mine so you guys can have a look :))Thanks!

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07 Nov 2025 18:25 - 07 Nov 2025 18:26 #338044 by PCW
I would measure the voltage between OUT0+ and OUT- when on to diagnose the issue.

it should  be much less than a volt

If OUT5 is used instead (this is suggested for Plasma systems) the voltage may be higher
but no more than 1 volt or so.

 
Last edit: 07 Nov 2025 18:26 by PCW.

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