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....  The engine is on it's way back to the customer, so that testing is over.

Yup, I figured the train has left the station.

I suspect this may never come up again.  And, if this was a systemic issue with PS3 boiler electronics, I'd think it would have been observed and reported albeit conventional PS3 operators aren't in the majority.

But if this comes up again by anyone, please tack on to this thread so I'll get a notification.  This is one of those curious cases that would be interesting to solve just for the sport. 

6-7 volts seems pretty low for PS-2 or 3 boards and winds up drawing a higher current flow.  Plus you intentionally had the motor in a stall condition at that voltage.  I always power up to 10V and then up to 12 once started up.  It was always brown out that damaged sensitive electronics in my prior life.  Not clean breaks in power.  So I am leery of trying to run electronics at a marginal voltage.  G

According to Jason and the service bulletins, as long as you use the proper chain files, you can mix-n-match EMI and non-EMI boards.  I know I just loaded a PS/3 board set with the relay board (non-EMI) with an EMI tender board, runs fine.

This is the service bulletin that addresses that issue: service_bulletin_101017a

If you don't have the correct code, you can run into issues.  I had this happen one time early on, the boiler board obviously was fighting itself and apparently turned on all the motor driver FETs at once.  Fortunately, I had my bench magnetic circuit breaker enabled, and the breaker tripped immediately and didn't cook the board.

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