RDC:
QUOTE(RDC @ Oct 4 2007, 12:03 PM)

If you Ohm out the Resistance between any two of the relays Common, N.O, and N.C. connections and then from any one connection set to Ground and it's open, then that will pretty much rule that out as being the cause and you're back to the controller or wiring being at fault somewhere.
I just performed this test on the relay, unpowered and not connected to anything. Connecting like points between the relay ports (Common to Common, NO to NO etc.) there was no continuity - all open. I did the same from the Common points to ground on the device and again, open circuit with no continuity. My most excellent meter has a buzz setting that is pretty useful for this type of test. No buzz on these other than for a connection between the NC and C on any port, which we would expect because this is the default setting for the device.
QUOTE
If the controller board works fine with everything disconnected that points to the relay or wiring causing it, if the relays contacts are measured and that's proven to not be the cause, then it's back to the wiring or how it's being wired.
I then connected the controller board via USB to the console and fired up the console by touching and holding the wires soldered to the Guide button for about 2 seconds. the controller was not connected to the relay at all.
I then used the wire touch method to test each wired button. Only the Guide, Start, and DPad-Left buttons work as this point. Others used to work but it appears that over time, possibly with my handling of the board they no longer work. I don't think the cause is a lack of physical connectivity because the connections appear to be fine still. An exception is that one wire has disconnected from one of the right-bumper terminals, and although I re-made the connection the Right-bumper still does not work.
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So, based on your comments and the results of this testing it would appear that I have toasted yet another board.
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The way forward...
All soldering/wiring to date has been done soldering to controller button pad locations on the top of the board. All required scraping away of the black anti-oxidant material prior to soldering (except for the bumper terminals).
I have yet to attempt to solder using the connections that you have suggested in your tutorials mostly because they were very intricate and at the time I was using relatively huge wires. I think I could pull it off now.
Do you think it would be better or would make any difference to use the solder points that you suggested in your tutorials now that I have more soldering experience and the proper wire for the job?
Also, would a wireless controller board be a better choice?