7i92 and G540 combination?

So you have no fault light on the G540?
Do the motors have holding torque?

No, as i have said they still just spin freely...

Did you try disabling the G540's chargepump? (it has a switch for this)

yes, I have... I gave it one more go but no luck...

OK so if you have the G540 chargepump disabled and the G540 estop input is defeated,
this is a hardware issue with the G540 (no signal from the 7I92 can affect this)

Do you have the current setting resistors installed in the G540 stepper connectors?

Yeah it is funny, like the g540 has an odd logic circuit that is somehow incompatible with the mesa hardware...
That is why i made this thread... i still require any information from others as to if they have had success or not.

As for myself, i am dying to get my project back on the road and need to pursue my back up plan,
which involves the use of the parallel ports on my old motherboard...

I bought a couple of PCI-e adapter cards which claim to be a mcs9901 chip...
do you mind helping me with the driver installation...

OK... You got it... there were still free wheeling...
It must have been that i suffered the drives at some point, and i replaced the motherboard only...
they passed visual inspection only...

I've just ordered a single replacement drive and i'll plug it in alone, see if that does it...
But I am not sure anything is wrong with any of the electronics...