Well just so we are clear:
The hardware it's self has no problems that I have heard of. ( when we say testing we meant testing pncconf's ability to configure it)
hand editting a HAL file is always possible. It's a little tricky because there is no official docs on the pinnames and parameters though that can be figured out.
As for using PNCconf.
First you must use the buildbot version of linuxcnc - it has the latest bug fixes - which is required to use PNCconf on the 5i25.
also you must add the firmware descriptions manually - not a big deal - see here:http://www.linuxcnc.org/index.php/english/component/kunena/?func=view&id=21670&catid=39#21670
I won't lie

It's not 100 percent tested yet - particularly around the spindle control ...
But for getting your basic XYZ machine functioning I think its a good place to start then add spindle then add A.
This way you can get a basic functioning machine while learning how the 5i25/7i77 HAL code works.
If you find a bug you can always hand edit the problem and report it here. I try to fix them as soon as I can.
I have a 7i76 and 7i77 card now to test with so bugs get squashed faster !
Chris M