Yes spool via spindle to analog module on the PLC.
The PLC it self handled the PID loop for Wire current, that included with the alarms to lower feed speeds or raise them to keep the current steady. Wire breaks also. The Feed/cut/current monitoring was the biggest pain in the ass. To me PID loops are the Darkest of : "Black Ju-Ju" magic. I STRUGGLED mightly to get it right. In the end, it worked fine, but there where several, several times I just about threw in the towel. If it wasnt for the PLC's abiltiy to do PID loops and realtime current control, it would have been a NO-GO.
I posted up the Screens I used for that machine, a while back in the screens section, feel free to use them (If you sell for money, remember your poor cousin scott......ehehehe). I have added more to them since then, but it was specific for that machine. I had to make some custom Threading Macros also, and Wire hiegth control macros. (had screen and physical controls for this as well. The machine was running well, last time I heard, about 1 year ago or so. OneCNC (the Cad/Cam), I use had just came out with 2 - 4 axis wire CAM, so it was a good time to take the plunge. It took me about 4 months to do the machine, mostly because I didnt know a DARN thing about these kinda machines, Still dont understand the DEEP stuff. I got ahold of a Sodic Applications engineer, and got very LITTLE information that was usuable. They gaurd those secreats like fort knox. In the End, I didnt fool with the Spark Gen, I just through trial and error got it to function with Mach and a PLC.
I suspect you could now do a C++ plugin that would have some kind of soft PID that could control, and handle the "Back ups" and other Wire issues that would avoid the PLC stuff.........
Scott