thank you all for your suggestions, a couple of separate responses:
AVTAS1:
dinky link works 100%, no need for a plasma-proof IR receiver. Call me lucky, but it worked on the first attempt, despite all the things I've heard and read on the web on plasma interference. It's mounted on the lower right side of a Pio503, 1 inch off the front plate, no tape required either. I can't upload any pics here, so here's a temp link to the initial setup (months ago)
Impaqt & Fred,
good points, I've already replaced all the CAT5 in my testing, it's not it (in this case). Regarding the 791-44:
1. tested dinky-link direct connect with new CAT5 to 791-44. 12V source checks ok. 12V/IR/Gnd cables used. No response on emitters
2. tested jbox direct connect with separate CAT5 to 791-44. 12V source still ok.12V/IR/Gnd cables used (I don't use status) No response again
3. Checked same receivers with ZC21 - same result- but didn't know the ZC21 won't work unless all 3 outs are used (thank you!!!) so I have to go back and retest tonight.
If I get the whole thing to work w/the ZC21 (temporarily), it'll mean the 791 is dead, otherwise I may have a bigger problem. I'll post an update later tonight.
thank you for the responses, greatly appreciated!