Ian, yes I suppose the external controller can throw up issues like that. I think Plasma is fairly well supported in the CSMIO controllers but suppose the only real way to know for sure would be to use it.
So if we go back to the corner dive control in as far as Mach when using the PP, is it simply an output that switches on/off or how does it work?
As for my plasma build itself, as said it will be a while away before I can start on the actual table. I did however get a cabinet from a friend which I will be using as the control cabinet, pics below are not that great but I think it will suffice.
Have managed to get some wiring done here at home, have managed to fit everything on it that I will need including the wee computer

Also a question for everyone, what size motor are people using for the Z axis?
Hood