Looking for opinions on controller box

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09 Sep 2026 18:40 #349505 by Burrow_87
Looking for opinions on controller box was created by Burrow_87
  
This is my first time building something like this cnc plasma table so looking for opinions on what I can improve before wiring everything.
7I96S
THCAD2
24v 16Amp psu
5v 4 amp psu
dm556 drivers (x, y1, y2, z, a)
5v relays for arc and torch control
8 opto isolators for limit switches (2 x, 2 y1, 2 y2, z, z touch)
e stop
If you room for improvement please chime in and let me know before I attempt to not make a rats nest of wires. 
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09 Sep 2026 19:46 #349512 by arcsynapse89
Replied by arcsynapse89 on topic Looking for opinions on controller box
Looks like its going to be a tidy control box. If it were my build I would put the 7I96S closer to the drives to shorten all the drive wiring, keep the THCAD2 and relays close to the 7I96S for the same reason.

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09 Sep 2026 19:52 #349514 by Burrow_87
Replied by Burrow_87 on topic Looking for opinions on controller box
Unfortunately I have to keep the card and power on that side so I can get to Ethernet, on/off switch and estop. The way the table is set up I can only get to that side of the control box when in use.

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09 Sep 2026 20:07 - 09 Sep 2026 20:08 #349516 by arcsynapse89
Replied by arcsynapse89 on topic Looking for opinions on controller box
 On one of my builds I used a pass through ethernet port mounted on the panel to use a small ethernet cable to connect to my 7i76e. Its hard when you have limited access but I overcame the problem with a short ethernet cable inside the box.   
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Last edit: 09 Sep 2026 20:08 by arcsynapse89.

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09 Sep 2026 20:30 #349517 by tommylight
Replied by tommylight on topic Looking for opinions on controller box
Get rid of the relay boards, opto boards and the 5V rails, you do not need them and they will only add to stuff collecting interference, Mesa 7i96S has isolated inputs and outputs, just check what output to connect the torch on as there should be two types of outputs on it.
Put the Mesa board in the middle vertically with LAN side down, THCAD and power supplies to the right and drives as they are.

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10 Sep 2026 00:03 #349523 by rodw
Replied by rodw on topic Looking for opinions on controller box
I agree with Tommy. Pointless adding additional failure points!

I would try and arrange the drives horizontallly as there is a risk the top drives overheat with the heat from the ones below. I have had this happen but at a lot more than 24 volts (which I think is too low, velocity and acceleration are king with plasma and you are limiting yours by the low voltage)

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10 Sep 2026 13:58 #349552 by djdelorie
Replied by djdelorie on topic Looking for opinions on controller box
My layout (no cabinet yet) is very messy, but here's an old photo of it:
www.delorie.com/photos/cnc2/PXL_20240324_210728573.html
I went with DIN rails for mine, one for mains power control (top) and one for low voltage (middle).  The mains rail has circuit breakers and contactors, and the contactors are wired into the estop chain.  The main logic power's contactor is wired into the on/off buttons so it defaults to off after a power failure.
You can mount power supplies on their sides if you need to save space.
Don't forget to leave space inside the box for vents and fans top and bottom.
Your estop should be more conveniently located.  Or buy more than one of them ;-)

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20 Sep 2026 20:35 #349758 by Burrow_87
Replied by Burrow_87 on topic Looking for opinions on controller box
After the critiques and some changes I have almost completed my controller cabinet. It’s not nearly as Tidy as I would like but I think the airflow should be decent enough to keep it cool. Thank to all the comments and helping a first timer out.
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20 Sep 2026 21:16 #349760 by Burrow_87
Replied by Burrow_87 on topic Looking for opinions on controller box
 
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