Differential encoder hard crashes the PC MESA7i77

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17 Mar 2026 12:25 #344401 by grossm5000
Hi everybody! I am struggling to get the MPGs working with my 7i77. These are differential encoders, and are wired into TB4 (z axis and x axis). Whenever I go to launch LinuxCNC, the computer crashes without warning like something is shorting or there is some hardware problem. 
When I unplug TB4, LinuxCNC will at least launch. 

Are there any jumpers i need to move around on the 7i77? The MPG wheels are supposed to run 5vdc…

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17 Mar 2026 14:42 #344414 by PCW
I would check the 7I77s 5V supply, my guess is that it droops
when you connect the MPGs, either from a wiring error or
too much current.

Does the 7I77 have 5V power supplied to TB1?
 

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17 Mar 2026 17:02 - 17 Mar 2026 17:04 #344418 by grossm5000
Replied by grossm5000 on topic Differential encoder hard crashes the PC MESA7i77
I am using 5V from the 6i25 card. I had also wondered if there was a wiring error somewhere, but I tested the MPGs with a multimeter found no errors. I double checked the wiring and everything is in the right place....so, this time I unplugged the terminal blocks and -you guessed it- LinuxCNC still crashes. It must have been a sad coincidence that when I plugged in the MPGs things went bad.I am using a Linux 6.1.0 -19-rt-amd64 kernel, which I just updated. That didn't fix the crash issues.I can open and play with everything just fine if I use a simulated machine, just completely crashes as soon as I try a non-virtual machine.I cant make heads or tails of the crash log. 
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Last edit: 17 Mar 2026 17:04 by grossm5000. Reason: added crash log

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19 Mar 2026 00:15 #344500 by grossm5000
Replied by grossm5000 on topic Differential encoder hard crashes the PC MESA7i77
I have 5v power from the computer. I unplugged ALL the terminals on the 7i77 TB3,4,5,7,8) reinstalled LinuxCNC (worried about kernel issues) and the darn thing still dumps me when I launch the program. 

I feel like I’m getting to the limit of the things I can do to make this work. Any help is welcomed. Anybody have any ideas??

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19 Mar 2026 00:37 #344501 by tommylight
Replied by tommylight on topic Differential encoder hard crashes the PC MESA7i77

Anybody have any ideas??

Yes:

I would check the 7I77s 5V supply, my guess is that it droops
when you connect the MPGs, either from a wiring error or
too much current.

If you have the encoder power wires reversed, that will for sure make the voltage drop and cause the failure.
But, some parallel cables have so thin wires inside that might also be the reason for the failure.
My advice:
-set Mesa boards for each to have it's own power supply
-find a good quality USB cable and cut the USB-whatever connector leaving only USB-A side and the wire, wire it to Mesa 7i77 as the power supply
-do NOT do this before checking the wiring and making sure it is correct.

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19 Mar 2026 01:51 #344508 by grossm5000
Replied by grossm5000 on topic Differential encoder hard crashes the PC MESA7i77
Hey thanks for the fast reply. I ended up powering the 7i77 with a dedicated 5v power supply. Flipped all the appropriate jumpers on the 7i77 and 6i25

i would also like to point out that I removed the terminal blocks for ALL the encoders, drivers on the previously mentioned TB…so it can’t be shorted or drawing too much power because everything is disconnected! 

I started to wonder if my 6i25 was dead. I don’t see any LEDs light up on it when I power up the PC. I also can’t find it with lspci 
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