The final problem of my controller install is solved. I wanted the cooling fans for the stepper drivers to be software controlled. When John saw them it was wired in permanently. My issue had been fitting an internal power supply for 12v systems, i.e fans, lights etc.
These little power supplies are highly efficient and dirt cheap.http://hobbycomponents.com/power/698-xl60009-dc-dc-step-up-boost-converter
It shares a common ground with the main 24v PSU. The controller has isolated grounds for different sections, it's not a good idea to bridge these grounds together as you can end up with lots of interference issues from electrical noise. Earlier back in the thread you may have seen nrml's post of the internals and the 12vdc regulator that is rated at 250ma. Well it's not enough to drive the fans direct but fine for powering a 12v reed relay (don't forget a back EMF diode). Got a Maplins dual reed relay as it was cheaper than the single ??? and wired it into the controller on M8/9 and the 12v internal supply.
The connections are soldered and sealed in Sugru, handy stuff but you need a number of jobs to make use of the once opened pack
Hot glue would probably have worked fine too.
I can now toggle the fans on off from the front panel as shown with M8 in bold. More to the point M8 is g-code controlled so I can turn the fans on prior to a job and turn them off after the job. If I needed that second reed can be used for anything else I might want to switch via M8, with no further load on the controller.
And that concludes the basic install for the router. YES, I am very pleased with this controller, it does more than I was able to do with the old router controller and LinuxCNC, that isn't a reflection on LinuxCNC, but more my abilities to understand and use it. I hope this thread has proved useful and inspires others to get one of these controllers and give it a go.