I would try these steps: change psu, change pool, change worker name, change to static IP. If still no-go reflash controller board firmware. If still no hash, disassemble miner, inspecting hash boards for solder defects (signs of overheating) try hash boards one at a time on known good controller. If still no hash - you may need hash board repair/rework/reflow.
I have no idea how i figured it out, but i did.
Seems that a chip (buck regulator) on the IO controller was having trouble... MP1484EN right next to the small red LED near the 18pin headers. I also had to power on the BeagleBone Board externally with 5v. Seems that something on the IO controller stopped passing power over to the BBB.
Once I had the BBB on, the IO controller still wasnt working right. The Fans were getting power, and eventually some activity happened on the IO board (red/green activity lights near ethernet jack) thanks to the BBB being on, but the 18pin headers (USB connections) there was nothing passing through to power that side on. I attached a PickIt3 to the hashboard via the ICSP header and violla!! the red LED lit up again. I separated the 2 boards and hooked the IO controller to 12v, powered on the 12v and started poking around with a volt meter around that buck regulator and suddenly the red LED lit up along with the green LEDs near the reset switches. I think i accidentally shorted 2 pins for a brief second? Whatever it was, it told it to work again almost as if it had taken a nap.
For the hell of it, i disconnected all, flashed new hex files to the PICs on the hash boards, connected everything again and reflashed the firmware. It all works but I still have to power the BBB externally.
