First of all the provider gave some wrong info, "to configure the lines as loop start with wink." -This is incorrect, loop-start IS NOT for DID and DOES NOT wink! You will need to configure the channels as T1-DID or T1-TIE, which ever is appropriate. The reason you are getting the 840C error code on the T1 module is because of the channel configuration. It shows 'stuck ringing' because the signalling bit pattern for loop-start is different for DID/EM, so the Legend thinks it is stuck with the ring bit on continuously.
Concerning the DID numbers and digits sent, since your existing is 3D with the Legend adding '6', I am assuming your dial plan has 4 DIGIT stations. There are a couple of ways to deal with the conversion. If you have the same provider, have them change the digit feed on the analogue DID trunk group to 4 DIGIT from 3 and delete the '6' digit added by the Legend to default. This would simplify testing and cutover. If not you can delete the added '6' when you cutover traffic to the T1, but you won't be able to place test calls because of the 'digits conflict' before cutover.
What do you mean by Channel Unit? Do you mean Channel Service Unit or CSU?
Remember you add the T1 channels/trunks by SS/PP, slot/port, not by dial plan assignments! So your T1 in slot 05 has channels 05/01 - 05/24 to be assigned as required. Now you may have some stuff left over from previous that needs to be defaulted or removed that may be causing the programming problem.
If you have not, do this: print out the Dial Plan, T1, PRI, and Trunk information. This way you can see what is there. This will make things easier to spot problems so you can fix them. If you want, you can post the printouts on TEK-TIPS, that way we can all see them. That goes for the error codes also.
On the 100DCD module the Yellow indicates channels in use or seized. The Red is an alarm condition. Does your CSU show an alarm from the Legend? You may be able to put a loop up in the CSU toward the Legend. This will tell you whether you have continunity between the two. Also check to see what leds are lit on the Telco's NIU at the demarc. You did mention that the provider tested OK with a loop....
Hope this helps!
If I missed anything let me know.
....JIM....