Servo Driver Plasma Retrofit

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10 Feb 2025 22:54 #321192 by kn612
Servo Driver Plasma Retrofit was created by kn612
I am looking for some guidance on switching my plasma table from hypertherm controls with servo motors/drivers to linuxcnc.  I have retrofitted my other plasma table that uses steppers to qtplasmac/mesa hardware, however the servo wiring is beyond me.  The current hypertherm controls cuts fine, however the microedge has been spontaneously rebooting and unreliable.I have a thcad 5 and thcad 10 already on hand, after reading around, I believe a mesa 7i97t is what I need?  Either way I am unsure of the wiring that needs done.  I apologize for my incompetence and am willing to learn.  I really like the qtplasmac interface over hypertherms softwareI attached pictures of the hardware. Would it be possible to leave the pcb that the servo drivers connect to on the back panel and replace the microedge controller with some mesa hardware and the needed power supplies and linux computer?

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11 Feb 2025 01:16 #321201 by PCW
Replied by PCW on topic Servo Driver Plasma Retrofit
Look like analog servos so a 7I97T is probably a good choice.
As far as wiring goes, do you have a schematic of the interface PCB?

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29 Jun 2025 15:34 #331007 by kn612
Replied by kn612 on topic Servo Driver Plasma Retrofit
Yes.  Here is a schematic that goes from the interface PCB to the hypertherm microedge for the drives.  I'm only familiar with stepper motors at this point so this is a little overwhelming.
Attachments:

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29 Jun 2025 22:17 #331017 by PCW
Replied by PCW on topic Servo Driver Plasma Retrofit
The basic motion I/O looks relatively straight forward

The A,/A B,/B, Z,/Z signals are encoder signals and go directly to the 7I97T

The Servo-Out pins go to the 7I97T analog out pins and the Servo-Out-Common pins
go the the 7I97T GND pins adjacent to the 7I97T analog out pins.

The drive enables are a bit more puzzling as It hard to tell if they are activated by grounding
or supplying a positive voltage 

 

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30 Jun 2025 02:31 #331020 by kn612
Replied by kn612 on topic Servo Driver Plasma Retrofit
Thank you

I will refer to hypertherms controller manual on the drive enables.

It looks like the thcad2 has replaced the thcad5 and thcad10? Its been a few years since I've messed with this stuff. My 7i96s table just works with zero maintenance.

Since there are 6 encoder interfaces on a 7i97t can I use the 2 left over for thc and ohmic?

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30 Jun 2025 02:52 #331021 by PCW
Replied by PCW on topic Servo Driver Plasma Retrofit
Yes, the THCAD2 replaces both the THCAD5 and THCAD10

And yes, you can use the 2 spare encoders for THCADs.

(if you needed more encoders, firmware that puts 2 or 3
'A' only encoders on one 7I97T 8 pin encoder connector
is possible)

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02 Jul 2025 02:28 - 02 Jul 2025 02:53 #331084 by kn612
Replied by kn612 on topic Servo Driver Plasma Retrofit
Here is a more detailed wiring pin out for the hypertherm controller.  However I haven't found anything about if they are activated by a positive voltage or a ground.  This chart says relay contact closure.  With that said, would I be able to just enable the drives with an external switch and relay?
Attachments:
Last edit: 02 Jul 2025 02:53 by kn612.

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02 Jul 2025 03:02 #331085 by PCW
Replied by PCW on topic Servo Driver Plasma Retrofit
It looks like you connect drive-enable-in to drive-enable-out
to enable the drive. This means the 7I97T's enable outputs
may work, but you would need to determine the polarity,
open circuit voltage, and closed circuit current. These can all be
measured with a DVM.

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02 Jul 2025 11:59 #331099 by kn612
Replied by kn612 on topic Servo Driver Plasma Retrofit
How do the 7i97t drive enable pins work? Do they supply a voltage?

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02 Jul 2025 13:57 #331104 by PCW
Replied by PCW on topic Servo Driver Plasma Retrofit
No, they are isolated optocoupler outputs rated 100 VDC and 50 mA max.
So the enable outputs may be used in place of relay contacts if the ratings
are not exceeded and polarity is observed.

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