MESA 5i23 7i44 7i49 7i37 8i20

If there is a working, hard-wired e-stop circuit then you don't really need anything in software.
You can use the loop-back from the sim configs:

# estop loopback
net estop-loop iocontrol.0.user-enable-out iocontrol.0.emc-enable-in

You probably also need to wire the enable pins of the 8i20 drives to digital outputs but those may already be in your axis HAL sections?

Have you had the motors rotating properly yet? i.e on the bench, not connected to the machine?

You expect following errors when setting up a servo system, So set the f-error limits quite big (in the INI) at first so you can see if things are moving in the right direction at least.

The first thing to try, make the _resolver_ scale negative on the axis that is triggering f-error.

I am now completely baffled. I thought this was a brushless servo system with resolvers, but you seem to be configuring for a stepper system.

I have just read back through this whole thread and I have come to the realisation that I haven't been as helpful as I have thought.

I thought I had previously given you a complete configuration, but that is not the case.

So, I think we need to make a fresh start.

I was hoping to be able to make an rmsvss8_6.xml file, but it is not possible to do that without access to the 5i23 hardware, and I am working away from home for the next week.

First, here is a basic configuration of a HAL and an INI file that ought to be fairly close.
Some things will have to be changed, but at least we will both be looking at the same files.

Extract the file into your linuxcnc/configs directory and you should be able to start it as a configuration.

I can't test it properly without actual hardware, so it might not work first time.

Once you have the basic configuration you are going to need to configure the motors.

If you look in the HAL file there are two items per axis that need to be set to suit your hardware before the motors will turn, these are the bldc poles (which I think, from what you have said are 10) and the "encoder offset" which is where the electrical "zero" of the motor is compared to the resolver "zero"

But, try the config as it is, it might even work...