Index of Failling = CABLES WRONG PINOUT

7i76 in Top of Photo was failed with:
24V Short Wrong Polarity @ TB1 +-
Burned U4 & U5 on 7i76

I attempted repairs yet unverified for reason cannot confirm HAL. 

With Hot Air Soldering I swapped U4 & U5 while also Loosing 2x Traces on U5 which I speculate may be simply a few I/O.  Otherwise, I option Hot Air Soldering more of the IC from 7i76D to 7i76 with hopes I may recover it.



The 7i76D in bottom of photo was Failed with:
a 24V to 5V Overload while connecting TB1 24V to TB3 5V. 

Supposedly the 7i76E is capable of wiring scheme  from TB1 to TB3.  The 7i76 & 7i76D are not. 

RMA with a Tech Diagnostic of 7i76D shown with some Red Stickers on the PCB.  

New to Mesa, I didn't know to use LED for testing & diagnostic! Wow what a difference! Now I can see what is going on!

7i92 was in fact turning 5X motors or lighting LED with OEM HAL. 

Evidently the Drivers or wiring are the reason the motors are not turning.

The Boards are responding Verified with LED...After shorting polarity on 24V TB1

Inputs / Outputs are now failed?  No Spindle , I/O

./7i76-7i88.hal:428: parameter or pin 'hm2_7i92.0.7i76.0.0.spinout-minlim' not found
./7i76-7i88.hal:32: Pin 'hm2_7i92.0.7i76.0.0.input-00' does not exist
./7i76-7i88.hal:32: Pin 'hm2_7i92.0.7i76.0.0.input-15' does not exist
./7i76-7i88.hal:32: Pin 'hm2_7i92.0.7i76.0.0.output-07' does not exist
21777

LED @ TB1 to TB6 #1 = LED FAILED. 
 

Hot Air Solder the Chips & IC from 7i76D to 7i76.
Well I Hot Air Soldered U4 & U5 IC Chips from 7i76D to 7i76. The I/O and Spindle fail to compile LCNC with I/O returns "input-00 does not exist".

If I continue Hot Air Soldering Chips from 7i76D to 7i76, I speculate I will eventually have a 7i76 Working Board with a 7i76D 24V Chipset I/O & Spindle.

This could potentially have a Short Circuit in the PCB Tracing so I don't think I should swap the chips from a 7i76D to a 7i76 on the 24V Side. Anybody know what is 24V and what is 5V on 7i76 PCB?

7i76 Inputs does not exist.
7i76 Encoder for Spindle does not exist
7i76 Outputs does not exist.

7i76 StepGens working correctly

I shorted 1x of 7i76 Step Gens at the Connector with a LED installed on the connector for testing. Test LED Shorted a StepGen Channel.

Identification of 7i76D Chipset for Hot Air Solder Swapping into 7i76 with Shorted 24V Field, Spindle & Encoder.

 

With Field Power applied I believe all test results for 7i76 Encoder, Spindle & I/O were "Does not Exist". 

If PNCConf assigns "TB5 Limit Switch" or "TB4 Spindle" or "TB3 Encoder" then LCNC should compile succesfully.  If LCNC fails compiling with "Does not Exist" then the board is failed per that specific PNCConf assignment per TB# correct?

To repair the 7i76 TB3, TB4 & TB5.... 
I should  be educated with "Xillinix JTAG Diagnostic Tool Sets". 

Otherwise, I would Hot Air Solder the 7i76D 24V ChipSet to the 7i76 24V Chipset.

7i76D RMA = UNREPAIRABLE
Initial Failure:  TB1 24V OverVoltage Pinout to the TB3 5V Input
Known Fail:  TB2 Step Gens 5V Chipset
Presumed Good:  TB3, TB4 & TB5 Chipsets

7i76:
Initial Failure:  TB1 24V Burn from Reversed Polarity
Known Fail:  TB3, TB4 & TB5 Chipsets compiling LCNC "does not exist"
Known Good:  TB2 StepGen Chipset is working, motors turning

Where 7i76D TB3, TB4 & TB5 Chipsets are Presumed Good
And 7i76 TB3, TB4 & TB5 Chipsets are Known Fail...

Because the 7i76 Turns Motors whatsoever, & the 7i76D does not exist entirely...  I would transplant Presumed Good chips from 7i76D to 7i76.  And not 7i76 to 7i76D because I could loose 7i76 and it has at least some working StepGens on TB2.

This Unknown Chip Swapping will probobaly fail:
PCB Could be different among 7i76D & 7i76.
Chips could have different Firmware among 7i76D & 7i76.
If succesful, Sourcing & Sinking Pinouts could then be reversed among 7i76D & 7i76.

As a last resort before buying another 7i76 with nothing to loose, I could...  
attempt Hot Air Solder Swapping Chips among failed boards...
identify & buy the exact chips, then install them unknown to the firmware installed in them....   
Receipt another 7i76.... 

The Diagnostic concluded with "Nema 23 Encoder Cable had Wrong Pinout different than documented in Nema23 Included Instructions.

This N23 Closed Loop Stepper Motor is a StepperOnline and every Encoder Cable on every motor in fact had a different pinout than the StepperOnline Specification Sheet for the exact motor.

Diagnostic was: Remove N23 Motor End Cap @ Encoder, Test Continuity of every Encoder Wire in the Cable to 7i76. Re-Pin the N23 Encoder Pinout according to Continuity Test of individual wires.

And motors then turned....

This "Wrong Pinout" was the Problem for me that "Cloaked" the actual N23 Encoder Pinout Problem leading to other diagnostics that failed with Short Circuited Burnouts.... Had the Pinout been correct initially, everything would have started right up... Where the pinout was wrong, ultimatley I Burned up 2x 7i76 Boards as a Novice trying to figure out why my motors werent turning.

Advice for the Mesa Novice CONFIRM 100%
Print & Verify ALL Cable Pinouts with CONTINUITY TEST before connecting any Voltages to Pins.
Test LED & confirm Signals @ MESA Boards.

Fail #1
DB25 Connector shipped from Ebay with the WRONG PINOUT. WRONG DB25 led to Burnout of 7i76 & repairs of 7i92.

Fail #2
I had a N23 Motor Encoder Cable with WRONG PINOUT. Led to burnout of a 2nd 7i76.

Hot Air Solder Swapping Chips from the 24V Side of 7i76D to 7i76 resulted "Does Not Exist" on
TB5 Limit Switch
TB4 Spindle
TB3 Encoder

I did swap a bunch of IC & Chips from the 2x boards, as much as I could reasonably swap. 

I speculate there is a communications link between the DB25 & 24V Chip Array that is failed and therefore, all the 24V Chip Array are Does Not Exist, so hot swapping chips all for nothing.

No luck, you have to know what you are doing and also have the JTAG Boundry Scan abilities.