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Its nice to see other Mesa users on here. Do you need the 10V power supply ie can't this be got from the VFD if it is only for spindle speed?

I am not sure I would connect the 24V -ve to the star...

200 steps per revolution will move the axis 10mm if using screw xx20 and if 1:2 as Dean suggested. so for 1mm -20 steps. But as you will use 1/8 microstepping, then 160 steps per mm. So...

Yes for acceleration reasons but at that length your still high chance of whip with 16mm screw. And why would you need Higher acceleration than 20mm could provide.?
At this length 20mm is better...

Yes go with the P5 AC bearings they are far superior and worth the extra cost.

15 Ground, if you can't machine the mating surfaces.

Orange plate not needed, punch down from plate 51 to the nut (see pic example).
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For a CNC router, like you're building, I would go for 'ZA' (medium) preload. Preload results in higher stiffness for the bearing, at the expense of reducing the life and increasing the driving force...

To give you an idea I recently built a Slaved axis 4x4 router with 20mm Dia 10mm pitch screws 1700mm length Fixed/Fixed ends with 2 x 3.1Nm steppers running 70Vdc on EM806 digital drives. It safely...

Oh very hard to answer because depends on the end fixing etc but I wouldn't go above 2000mm and at that I would have Both ends with Fixed bearings and slight preload on them. When I build 4x4 size...

Here's a spreadsheet to help when working out timing belt lengths. There are plenty of these calculators online, but I made this as I find it makes it easier to compare options when you can list...