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Found one instance:
forum.linuxcnc.org/27-driver-boards/5339...-over-current#306578
Also, is the 6V1 a regulated or unregulated rectifier?
What is the voltage on that rail when everything is powered on and when everything is powered off?
If you have a scope, do a trace of that rail while flipping the some big relays on/off, see how much they induce to the DC side.

Use PncConf to create a basic minimal config for 7i92 with 7i77, then we can modify it to fit the 7i97T and give it a try.
Simple 3 axis config, no spindle, no I/O, no MPG, nothing else.
Also upload one of the existing configs that run so we can get the card addresses.

If that is actually the line powering the Mesa boards, I have made an artistic representation of the issue, see attached:


As mentioned many times here on the forum by several members, do NOT cut on/off the DC side of power to Mesa boards... and stepper/servo drives.
I will leave it to PCW to explain why as i might make a mess.

@ Rüdiger,

Max acc scurve = 2 x acc.
at scurve inflection point the
Scurve acc = 2 x acc.
see  scurve lib abstract.
 

Hello,
I tested further and apparently the acceleration is not limited. In the ini it says 'MAX_ACCELERATION = 5000' in the halscope at approx. -10000.

Gruß Rüdiger

 

So i received the card back with no reported problems but i still cant get any output to my drives. I completely reinstalled Linuxcnc, Mesa flash and Mesa CT with the same results. I'm at a total loss with this thing.. I tried to use the Pncconf wizard but it doesn't support the card I bought. Would i be better off sending this on back and getting some of the older ones that are a little more user friendly?

Have you had a look at the included rosekins?
linuxcnc.org/docs/html/man/man9/rosekins.9.html

There is is a sim config:
github.com/LinuxCNC/linuxcnc/blob/master...s/rose_engine/README

I really appreciate you guys looking at and commenting on this. I would not have thought of that, but I never touched that part of the Maho wiring, so it still has the hardware inhibits on the main 3Ph contactors.
 

Output-03 only runs one of the 24V relays to control 24V to one of the little gearbox shifter motors.
 

I have had the shared memory warning too. I don't think that's related to ethercat, it is something else. I ignored the warning and well it didn't go away but I can't see it causing a problem.

So the drives are in OP, good.
But you use that minimal hal file, the four lines hal file you attached?
You now need to have a hal file describing the movements and limit switches and so on. From a real linuxcnc system.
I guess you have a lathe in mind.
Your drives are cia402 drives, one way is to start from the cia402 example, link here. github.com/dbraun1981/hal-cia402/tree/main/example
You can have a look in the example ethercat-conf.xml for inspiration, but use your own.
The hal file you can use. It's for one axis, you extend it to a Z axis.