[davy182]

I need some advice so that I don't over act on running things through terminal blocks. What elements should definitely run through the blocks?

Should encoders run through it or come directly out of the drives.
Should power going to servo armatures run through them.
I figure 5v power and 80vdc power distribution should go through the blocks.
Any suggestions is appreciated.

[Al_The_Man]

You can run virtually any signal you want through DIN terminals, keep encoder away from power and make sure any shields are carried over between in and out.
Al.

[davy182]

Al, if it were your box what would you bother wiring through the terminal blocks.

[Al_The_Man]

If at all possible I stay away from intermediate terminations, one of the upsides though is if you need to monitor or temporarily disconnect a line for testing that has a sealed connector or other type of un-accessible termination.
It is normal though to set up all power and power commons and Earth ground in a DIN terminals with the optional Bus straps across the top.
Al.