Hi All, I am having some problem with UC100 motion controller. Below is my configuration.

Win 7 32 bit
Intel I3 6100
UC100 Motion Controller (V2.148) + PMDX 122 Interface Card
Neuron Lite THC Controller
Mach3 Version 3.043.066
PMX 105 Hypertherm Plasma

When normally jog and test run, no problem will occur. But when start to pierce by plasma, mach3 will show error as shown in photo provided below. This only happen when piercing thick material 15 and 16 mm by 105A consumables. When i using Finecut consumables to cut 1.5mm plate, no issue found. So far i did change a screen usb cable, new motion controller, relocated to less noise place and reinstalled whole software.

Also after UC100 motion controller not respond, mach3 will go into a lag status, need to close down and reopen then solve. UC 100 needs to replug in also.

Any help will be appreciated.

Thanks
Thong

Did you ever figure your issue out?

Definitely an electrical noise issue. Your plasma system uses very high frequencies. Make sure its isolated from everything and youve put EMI filters where they need to be and Ferrite chokes too. On our big machines we build we completely isolate any plasma equipment from the machine earth (were talking nylon stand offs etc) then a seperate earth linking all plasma equipment straight back to the main earth. If you have an oscilloscope youll see the voltage spike when you pierce (a spike most likely in your low voltage stuff like 24VDC (were talking 300V or more voltage spikes). 

Just a note - USB never seems to play well on Plasma, I tried and failed, went back to parallel port which is not much better but seems ok at 45A plasma and only on a Hypertherm - tried three other makes and all failed.

If/when i build a new table it will be with ethernet connection as that is far more stable in poor conditions and you cant get much worse than plasma.