Recommended MESA board for setup

Hi all,

First time posting but regular trawler. 

I have decided to try make the switch to LinuxCNC but with my machine needing to be run a lot I am looking to do it with as little downtime as possible. 

I'm interested in going the MESA route because I have plenty of PC parts but don't want to rely on it for steps. Ideally I am after a MESA board or boards that will accommodate my machines requirements as the machine wont be upgraded much further.

Some specs:
5 closed loop stepper motors and HBS86 drivers (2 on the X-axis)
4 axis X,Y,Z and rotary A (5-axis for gantry squaring)
3 limit switches for homing (4 limits if gantry squaring) 
VFD Spindle controlled using PWM-DC 0-10v converter (not used for tapping or threading)
Coolant relay enabled (not spindle coolant)
Probing (currently only used for Z)
Enable/hold output for spindle coolant flow switch and drivers to stop program during fault events
Typical max feed is 10,000mm/m on Z and 20,000mm/min on X/Y but also occasionally go out to 50,000( over 20,000 not essential if a limiting factor and Z never exceeds 10,000) 
X/Y run 25steps/mm and Z runs 200steps/mm
Every input and output runs at 5vdc so all the higher voltage gear is run separately 

Cheers for any help




 

Thanks Tommy

I forgot to mention I couldn't go 7i76E because of trouble sourcing it.

Other than price is there any big reason for peoples preference for the 7i76e over the 7i95?

The HBS86 driver handles the motor encoders. I use similar closed loop drivers with my mill and have no problems using the drivers to close the loop (without running the motor encoders through LinuxCNC). I have the driver alarms connected to inputs running into e-stop latches. The closed loop stepper driver alarms catch 99% of mechanical problems (forgetting to unlock an axis, spindle bumping vice or clamp, etc..). Phase 1 of my mill project was glass scales and LinuxCNC just working as a DRO. When I updated, I kept the scales and use them as feedback. They gives me a warm fuzzy feeling to have an independent measurement but I don't think I would miss the scale encoders if they were gone.

On my mill, I use a 7i92 with a 7i85s for the XYZ and spindle encoders and a 7i75 breakout.

On my lathe, I use a 7i96. I use the expansion header to connect a G540 and use glass scales for the XZ encoders and another spindle encoder. Goal this week is to control the VFD with PWM (probably through the G540).

On my router, I use a parallel port connected to a G540 gantry. I used the four inputs for the XYZY homes and just ordered another parallel port so I can connect a tool length probe, 3d probe, VFD alarm, and power supply ok signals.

I'd definitely stick to the ethernet Mesa boards.

I'd recommend going with four limit/home switches for the gantry squaring. (I just committed an update for the 2.8 configs/by_interface/parport/gantry example.)
When you do your i/o count include pins for the driver alarms.
Does your VFD have an error output???
Does your power supply have an error output???