All good ideas guys… and actually this is starting to look like it may well need 2 boxes, or a PC case larger than 24x24. Here is my mockup using everything I can think of at the moment, inside a 24x24 box with 1.5" wide wireways (actual layout is 21x21 to fit on the backplane):
I want to keep the HV wiring and components separated from LV, and high current separated from signals… preferrably HV stuff on bottom. So this is far from an optimized layout, but it shows how cramped it’s getting. Note that all the components on top are DIN rail mount, and everything on bottom is surface mounted. The pi of course can also be din mounted. The 6-pack takes up a lot of area, but can’t really be mounted any other orientation without making it a royal PITA to work on. It probably could also use another inch of padding all around to give room for ferrules and a USB port. Pi has room for USB/HDMI/power as shown.
The VFD is shown mounted to the backplane, taking up a 5x7 inch rectangle with 7" depth. It can also be mounted to the side, which would make it a 7x7 square with 5" depth. The VFD is the deepest component whether I mount on the back or side. So how it mounts will determine the required depth inside the box.
I haven’t researched a whole lot as I have been away from my PC the past week. I’ve seen a new steel 24x24x8 box with backplane that would cost about $140 brand new at Homedepot ouch. A pair of 12x12x8’s would cost the same, and give me a lot less room to work with.
Any suggestions regarding layout, or additional advice on enclosures is much appreciated. It is normally my style to cram things in a lot more than this… like a 16x16x8 doing it “my way” without wireways or room to work, lol. However, I do want room to grow, and would appreciate having something that looks good and is easy to work on (worth $140 to me anyways).
[edit: More info… the cluster of DIN to the left is all low volt (fuses from PSU and relays, signal buses, relays), DINS to the right are all HV stuff (buses, breakers, and PSUs). Of course, the transformer and VFD are also HV items. There’s no main breaker in there yet either… was considering adding an external toggle for the 220V feed instead, as the breaker in my home load center together with the PSU/VFD breakers seem adequate for safety/convenience. I may also just run a separate 120V line so I can keep the pi always on without the transformer. In this case, the transformer may not even be needed.]