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Should I connect one transformer lead to ground (the plug is 3-prong, the chassis is grounded steel)?

NO!
Connect ground only to box/chasis and to shielded cables.
Amps should be enough, move on.
Transformers can handle a lot of abuse, small overloads are no problem at all. After you power everything and have it running for 10-15 minutes, do check if it is heating from time to time, and even if it gets hot after and hour or two of work, as long as you can keep your palm on it, it is OK.
Human hand will have issues above 50 degree C, at 80 it burns like hell, and you will always know if the temp has gotten over 100 as your skin will remain attached to whatever you are touching, and fingers will turn shiny!

I'll have to leave this to Rod & others. It's not something I could really test other than the installation bit.

Nice! If you need someone to play with it I'm here

Thanks for your reply I will look it over as soon as I have time. (: (:

regarding EtherCAT driver for rpi5 ethernet:

gitlab.com/etherlab.org/ethercat/-/issues/104

RPi 5 uses the

macb

driver (Cadence GEM) and not

genet

. So I guess you have to use a Raspberry Pi 4 if you want a native driver.

I'll have to add the 7i78 spindle.

JT

The spindle basically works now. But... when Linux CNC is not running, the spindle ramps often up to full speed. (I hooked the Enable pin of the drive to a +5V pin of the TB3, so obviously the PWM pin must put out full voltage when the software is not running yet)
What should be the output of the pwmgen, when no linux CNC is running?

I think I could circumvent this by connecting one output of TB6 to the Input of the Spindle drive.
Problem: Output is set up for 24 V and I have no idea if that will damage the Spindle drive.

Is it a usual approach to just put resistors into the wiring?
 
Should it be even O.K. to just install one Resistor (R1) in the output line and cancel R2 altogether?

 

Yes, sorry, did not mention it as that is always implied, normally 4 motors then add as needed.
BTW you can do Voron with just one Z motor and have all side coupled with shafts and pulleys/belts, but that leaves auto squaring/leveling out.
Most of my Vorons have 2 boards, this was very nice for the big one (460x460x1200) as one board is on the gantry and only needs power cable USB cable, while the other board is under taking care of 4 motors and the bed. Any chance i get, i will modify the rest like this, broken cables are the only issues i had with them, ever, due to small radius of cable chains and bad quality cable.

where then in Linux are these signals generated, how to register them for a specific driver And where is the PLC of the machine written?