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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.  

Thank you for that.

Update: I have the pc at this moment at home, so i can do some tests while doing my work.
When i start latency-histogram and run it for some time (e.g. 15 min) with 3x glxgears the base thread looks good. Depending on the cpu bios settings i have stable max us of 20.000, but i found out that when i addionally start a youtube video (720p), the latency goes up, pretty quickly, almost directly after starting the video and then the latency jumps to 45000 then 60.000 and who knows how high it goes but then of course it doesnt matter anymore. 
Of course i have to connect the pc back to the machine and see if it starts without unexpected real time delay and if the machines runs smooth, because after going from wheezy to debian 12 i had the situations where there latency-test (not histogram) showed good results in for a short time but the motors didnt move as they should.

While writing this post, the latency-histogram is still runing and still at 20.0 us. Maybe i am able to get it to work, but it seems that the vga might cause the latency spike and thats why i get a unexpected real time delay on start up.

What i could do next is to buy better ram, because one stick of the ddr3 1600mhz (2x4gb) ram that i had from my last main pc is not working, so i am currently using some old 1333mhz ddr3 2x2gb rams.
Also a onboard vga might give better results, but i dont have a pc with integrated vga to test it.

Perfect! Not sure what plasma cutter you have but if it was say hypertherm, a surface mount circular connector that just pushes into the socket on the machine and you would have a nice complete self mounting package. I used the 7i76e spindle relay for torch on so there is nothing wrong with your photo diode. You just need to add a pull down resistor on the arcOK as discussed in the qtplasmac docs. 

Of course if you had a XPR hi def its Ethercat anyway!