mesa 7i76e stepgen failure

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03 Jun 2026 21:31 #346879 by peterdownunder
mesa 7i76e stepgen failure was created by peterdownunder
Probably a lost cause, but just in case ...
Turned on my CNC and the Z axis did not move.
After swapping out the stepper driver found that the stepgen no3 on the mesa was not outputting any step pulses as shown on my oscilloscope. Direction pin was changing as expected.
Changed it to number 4 and all is ok.

Assume just a hardware / output driver issue.
Is this a common fault on these cards. It is at least 5 years old. It lives in a pretty protected environment.

At this point I only need 4 stepper outputs so can live with it as is.

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03 Jun 2026 22:10 - 03 Jun 2026 22:12 #346880 by PCW
Replied by PCW on topic mesa 7i76e stepgen failure
Failed stepgen outputs are most likely due to a problem with one of the
the output driver chips. For stepgens 0..3 these chips are a 74ACT541 (for the + outputs)
and a 74ACT540 (for the - outputs)

Does the  step3- output work? If not, it may be a deeper hardware issue
(PCB or soldering issues) These kinds of issues are rare.

Bad step/dir outputs caused by driver chip failure  are not rare but usually
traceable to accidental contact  of the step/dir pins to a voltage outside
the 0 to 5V range perhaps during initial wiring.
Last edit: 03 Jun 2026 22:12 by PCW.

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03 Jun 2026 22:12 #346881 by tommylight
Replied by tommylight on topic mesa 7i76e stepgen failure
No, not a common fault at all, i am sure i have over 80 Mesa boards (more probably) and none of them ever failed, and they are mostly on industrial machines, and all are in use daily, some are never switched off, for over 10 years. And most are on plasma machines, by far the worst machines for EMI/interference.
What machine is yours?
Did you disconnect the stepper drive when checking with scope?

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04 Jun 2026 00:27 #346887 by peterdownunder
Replied by peterdownunder on topic mesa 7i76e stepgen failure
Firstly made a minor mistake on the numbering i.e. 3rd stepgen therefore stepgen.2

This is a small cnc in my home so pretty clean environment using DM556 drivers.
Scoped it with the driver disconnected and hooked between gnd (first pin) and step+.
Figured that since the dir pin toggled when I jogged the Z up and down, that all programming was connect.
Scope looked fine on stepgen.3 and Z now works on that channel.

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04 Jun 2026 00:31 #346888 by peterdownunder
Replied by peterdownunder on topic mesa 7i76e stepgen failure
Also another thing, is that I have changed the stepper driver to a new one as I thought initially that might be the problem.

*possible* that the original is faulty and took down the output. Not prepared to test it on another channel though (:

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04 Jun 2026 02:24 #346890 by tommylight
Replied by tommylight on topic mesa 7i76e stepgen failure
Drives usually have only optocouplers on the inputs, so chances are low for it to short, higher chances of loosing sensitivity (light output as inside the is an LED and a photodiode).
Much higher chances of interference from the spindle and/or VFD that caused a spike, might even be moisture messing things up.

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