From what i understand,

- You're using the same wiring harness for both cams. ie, connectors/cables are the same for both cams but only one cam works in direct case with this same harness.
- Your osd cable is in proper working condition.

Check continuity of all cables involved, connector to connector when plugged in. Separately check ohm range resistance btw video & ground wires of osd cable.

The section from hs1177 to the wiring harness is different  as it a different connector from other cam. So it's a possibility. Will try continuity. ..

I did a continuity test for the foxeer cable. . Micro jst to Jr type... power and ground passed but video failed 

There you go. Fix it.

By foxeer cable, i hope you meant the normal type.

The regular cable supplied with it . I have asked to RCH ... because it a new unit and I don't want a cut or tweak it to operate it rt.. after all its a brand new unit I expect it to work like new  and more over these micro jst connector tors are very rare to get

Cable issues are mostly user fixable unless ofcourse it's broken or crooked beyond hope. I wouldn't invoke warranty for such, but it's your choice. I think there will be access windows to all 4 pins on the connector itself. See if you can tap into it & get a direct feed on tv from cam. That will confirm the fault. If you're up to it, solder directly into cam pins if not planning to move it around much.

This cable works with the HS1177: http://www.surveilzone.com/20cm-power-video-4pin-1.25mm-to-2.54mm-servo-fpv-cable-pa1214

Quote from: sandyx on July 26, 2016, 12:39:20 PM
Cable issues are mostly user fixable unless ofcourse it's broken or crooked beyond hope. I wouldn't invoke warranty for such, but it's your choice. I think there will be access windows to all 4 pins on the connector itself. See if you can tap into it & get a direct feed on tv from cam. That will confirm the fault. If you're up to it, solder directly into cam pins if not planning to move it around much.

Already did that and finally was able to see the video ...direct connection. .. and yes am not ready to open the case and solder ...

Thank you guys for all suggestion  was able to figure out the issue with your help !!

And today I got the replacements cables from RCH, and actually Kumaran sent me two .. WoW ... Thank you so much Kumaran/ RCH for your excellent support till resolution !!!