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The idea to power it from 24V stuck, I am going to do it that way. Will get rid of a 5V power supply in the cabinet.

The voltage reader can fit in a connector, that would be possible, but not the EtherCAT components. They need say 100x60 mm as it is today.
Two-sided and dense packing, no still not inside a connector.
I will try that idea to put the EtherCAT function on the plasma cutter. It doesn't make sense for me since it is a matter of 0.5 meter, but why not?
Could be a question of how long the ethernet cable can safely be versus how long the I2C cable can be.
That power injector/ejector is here on Monday.

I have a Herocut 55i, it is all very small scale, hobby and prototypes for my enjoyment.
I get voltage, arc-ok and can control torch-on. Power level, air pressure isn't, well require more work than I want to spend right now.

Must also say I am very happy with QtPlasmaC, works really nice.

    Not sure if I'm posting this in the right place but I cant get past the joint following error to tune my -10/10 volt servos. I've reloaded everything several times with the same result... When I enable the drives the servos start drifting for about .001/.002 and then the following error. I am THE most computer illiterate person on earth and have no idea how to fix this thing. I've been trying for the last couple of months to get it going but can't get past this. With the help from this forum I've been able to get the network, mesa flash, mesa ct and card wiring complete but am stuck on this one.