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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.
 

I still get the shared memory buffers warnings (as before) but linuxcnc will start. The drives show to be in OP status and the linuxcnc shows the axis moving, but the steppers do not move