7i96S card arrived what setup is recomended

So the fault pin is only cleared when the drive is re-enabled?

If so, you might need some hal logic (and + ones-shot perhaps) to mask the error until a bit after
the change to machine-on state

So the fault pin is only cleared when the drive is re-enabled?

That sounds about right and the fault is preventing me from clicking the machine on in the ui.

So should something like this work:

Expected result would be, the alarm triggers the oneshot, which then triggers the amp-fault-in and in turn turns off the machine. The fault is also cleared 0.5s after the oneshot fires thus allowing me to turn the machine back on an clearing the ALM signal.

I'm not sure if auto resetting makes sense. Often the alarm is raised when a motor overheats and it will need time to cool before engaging. An alternative would be to incorporate the enable signal into your estop circuit so the drives are only enabled when estop is off.
Cycling the estop will clear the error.

I'm not sure if auto resetting makes sense.

I don't think this would auto reset since I would still have to power the machine on in the ui to reset the drives. Also, the CL57T only allows resetting in this way for following errors and not overheating.

Currently my external estop is wired into the contactor latch for the drives/spindle power. Should I consider changing this?

I would use a new output pin that follows the state of estop. 

Yeah, I was already doing that with the other NC contact from the estop to the Mesa input and tied into the estop-latch logic in hal.

Hello.
One 7i96s card on a lathe lost the encoder signal (it cames from a spindle driver on a differential line - as on 4th page ).
An other 7i96s card  ("from the box") has the same issue with the encoder and has the new W7 jumper for RS-485 - not used yet, just powered on)
I have connected a TTL encoder for test - that is why the jumpers on left hand.
On the table one card works, so i replaced it. But now i have a used (± a year) card, and a new one with no encoder input. We using them for lathe, so we need the encoder input for threading.
Can it be solved somehow? Re-soldering a component?
     
   
 

I would  first, disconnect  the encoder, jumper the encoder inputs for TTL mode
and then test the A,B and Index inputs by grounding the A+, B+ and INDEX+ pins
and watching the hal pins for these in halshow. They should change polarity when
grounded vs open.

The 7I96/7I96S encoder inputs are normally fairly rugged but can be damaged by EMI spikes
of greater than 25V. This can happen in a test setup where VFDs or spindle motors couple
the 400V or so square wave drive power into the encoder signals because of insufficient
grounding/shielding.

The Encoder input chip on a 7I96S is a 26LS32 (U12)

5 years using mesa cards and this is the first time i had issues.  The cards i'm ordering via cnc.prom.ua (the same price ±, like on the official site but not need to pay customs and tax) Usually they came already opened (the sticker is damaged), maybe they testing it, or just puts their logo.
I found only DS26LS32CM,  AM26LS32AC  , AM26LS32ACDR,  26LS32AC  (which can be used?)

So, the used 7i96s card, which was on a lathe. Signal wires on one side of the El.box, power wires on the other side of the El.box - nearly one year worked well:
ch-a - working
ch-b - not working
ch-i - not working
   

The new 7i96s (rev E was not used and not tested after arrival) :
ch-a - working
ch-b - not working
ch-i - working