(LPT) Debian 12 Latency spikes/unexpected real time delay. Looking for solution.

So, i could open Linuxcnc ones after i got a error message on start up, but after reboot i get the error message all the time, so i am not able to start linuxcnc.
I wanted to attach the report file, but cant upload that file type, so i just paste it here. sorry that but i want out of the workshop now, i have enoug and mz hands a freezing.

Error report created by /usr/lib/tcltk/linuxcnc/show_errors.tcl:

Print file information:
RUN_IN_PLACE=no
LINUXCNC_DIR=
LINUXCNC_BIN_DIR=/usr/bin
LINUXCNC_TCL_DIR=/usr/lib/tcltk/linuxcnc
LINUXCNC_SCRIPT_DIR=
LINUXCNC_RTLIB_DIR=/usr/realtime-5.4.290-rtai-amd64/modules/linuxcnc
LINUXCNC_CONFIG_DIR=
LINUXCNC_LANG_DIR=/usr/lib/tcltk/linuxcnc/msgs
INIVAR=inivar
HALCMD=halcmd
LINUXCNC_EMCSH=/usr/bin/wish8.6
LINUXCNC - 2.9.4
Machine configuration directory is '/home/cncrouter/Downloads/XYYZ'
Machine configuration file is 'XYYZ.ini'
INIFILE=/home/cncrouter/Downloads/XYYZ/XYYZ.ini
VERSION=1.1

check_config:
  INCONSISTENT coordinates specifications:
               trivkins coordinates=XYYZ
               [TRAJ]COORDINATES=XYZ

PARAMETER_FILE=linuxcnc.var
TPMOD=
HOMEMOD=
TASK=milltask
HALUI=halui
DISPLAY=axis
COORDINATES=X Y Z
KINEMATICS=trivkins coordinates=XYYZ
Starting LinuxCNC...
Starting LinuxCNC server program: linuxcncsvr
Loading Real Time OS, RTAPI, and HAL_LIB modules
Starting LinuxCNC IO program: io
emc/iotask/ioControl.cc 786: can't load tool table.
Starting HAL User Interface program: halui
linuxcnc TPMOD=tpmod HOMEMOD=homemod EMCMOT=motmod
Found file(REL): ./XYYZ.hal
Found file(REL): ./custom.hal
Starting TASK program: milltask
Starting DISPLAY program: axis
USRMOT: ERROR: command timeout
emcMotionInit: emcTrajInit failed
USRMOT: ERROR: command timeout
emcMotionInit: emcTrajInit failed
RTAPI: ERROR: Unexpected realtime delay on task 1
This Message will only display once per session.
Run the Latency Test and resolve before continuing.

waiting for s.joints<0>, s.kinematics_type<0>
waiting for s.joints<0>, s.kinematics_type<0>
waiting for s.joints<0>, s.kinematics_type<0>
waiting for s.joints<0>, s.kinematics_type<0>
waiting for s.joints<0>, s.kinematics_type<0>
waiting for s.joints<0>, s.kinematics_type<0>
waiting for s.joints<0>, s.kinematics_type<0>
waiting for s.joints<0>, s.kinematics_type<0>
waiting for s.joints<0>, s.kinematics_type<0>
Shutting down and cleaning up LinuxCNC...
task: 259 cycles, min=0.000012, max=0.010209, avg=0.009507, 0 latency excursions (> 10x expected cycle time of 0.010000s)
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments

Debug file information:
note: MAXV     max: 80.000 units/sec 4800.000 units/min
note: LJOG     max: 80.000 units/sec 4800.000 units/min
note: LJOG default: 80.000 units/sec 4800.000 units/min
Waiting for component 'inihal' to become ready.....................
A configuration error is preventing LinuxCNC from starting.
More information may be available when running from a terminal.
1820
1889
Stopping realtime threads
Unloading hal components

Kernel message information:
[   94.539313] I-pipe: head domain RTAI registered.
[   94.539441] RTAI[hal]: mounted. ISOL_CPUS_MASK: 20.
[   94.539447] SYSINFO - # CPUs: 6, TIMER NAME: 'lapic', TIMER IRQ: 4355, TIMER FREQ: 6270499, CLOCK NAME: 'tsc', CLOCK FREQ: 1404706000, CPU FREQ: 1404706000, LINUX TIMER IRQ: 4355.
[   94.549853] RTAI[malloc]: global heap size = 2097152 bytes, <BSD>.
[   94.549901] kstacks pool size = 524288 bytes
[   94.549903] RTAI[sched]: hard timer type/freq = lapic/6270499(Hz)
[   94.549904] linear timed lists.
[   94.549908] RTAI[sched]: Linux timer freq = 250 (Hz), TimeBase freq = 1404706000 hz.
[   94.549912] RTAI[sched]: timer setup = 159 ns, resched latency = 0 ns.
[   94.554302] USERMODE CHECK: OK.
[   94.554306] USERMODE CHECK PROVIDED (ns): KernelLatency 1772, UserLatency 2726.
[   94.554308] FINAL CALIBRATION SUMMARY (ns): KernelLatency 1772, UserLatency 2726.
[   94.572540] RTAI[math]: loaded integrated musl libm version 1.2.3.
[   94.668559]
               identityKinematicsSetup: coordinates:XYYZ
[   94.668564]    Joint 0 ==> Axis X
[   94.668566]    Joint 1 ==> Axis Y
[   94.668567]    Joint 2 ==> Axis Y
[   94.668568]    Joint 3 ==> Axis Z
[   94.668570] identityKinematicsSetup: Recommend: kinstype=both

[   94.681692] config string '0xc800 0xdc00 out'
[   98.568211] RTAPI: ERROR: Unexpected realtime delay on task 1
               This Message will only display once per session.
               Run the Latency Test and resolve before continuing.
[  103.953414] RTAI[math]: unloaded.
[  104.031797] SCHED releases registered named ALIEN PEDV$D
[  104.034092] RTAI[malloc]: unloaded.
[  104.139720] RTAI[sched]: unloaded (forced hard/soft/hard transitions: traps 0, syscalls 0).
[  104.161297] I-pipe: head domain RTAI unregistered.
[  104.161529] RTAI[hal]: unmounted.

---

Info report created by linuxcnc_info:
The file:    /tmp/linuxcnc_info.txt
can be posted to a forum or a web site like:
     pastebin.com
in order to provide information about the linuxcnc
system and configuration.

                Date: Thu Feb 20 06:49:14 PM CET 2025
            UTC Date: Thu Feb 20 05:49:14 PM UTC 2025
        this program: /usr/bin/linuxcnc_info
              uptime: 18:49:14 up 2 min, 1 user, load average: 2.21, 0.88, 0.33
     lsb_release -sa: Debian Debian GNU/Linux 12 (bookworm) 12 bookworm
            linuxcnc: /usr/bin/linuxcnc
                 pwd: /home/cncrouter/Downloads/XYYZ
                USER: cncrouter
             LOGNAME: cncrouter
                HOME: /home/cncrouter
              EDITOR:
              VISUAL:
            LANGUAGE: en_US:en
                TERM: dumb
           COLORTERM:
             DISPLAY: :0
             DESKTOP: lightdm-xsession
        display size: 1680x1050 pixels (444x277 millimeters)
                PATH: /usr/bin:/home/cncrouter/Downloads/XYYZ/bin:/usr/bin:/usr/local/bin:/usr/bin:/bin:/usr/local/games:/usr/games

uname items:
         nodename -n: debianhost
      kernel-name -s: Linux
      kernel-vers -v: #1 SMP Sun Feb 16 14:27:43 CST 2025
          machine -m: x86_64
        processor -p: unknown
         platform -i: unknown
      oper system -o: GNU/Linux

/proc items:
             cmdline: BOOT_IMAGE=/boot/vmlinuz-5.4.290-rtai-amd64 root=UUID=329e52b2-83ca-4098-8506-02f3ac2d7461 ro quiet isolcpus=5
          model name: AMD Phenom(tm) II X6 1055T Processor
               cores: 6
             cpu MHz: 1403.309
             parport: 0000-0000 : parport0 0000-0000 : parport0 0000-0000 : parport1 0000-0000 : parport1
              serial: 0000-0000 : serial 0000-0000 : serial 0000-0000 : serial

Versions:
/usr/bin/linuxcnc_info: line 154: gcc: command not found
                 gcc:
              python: Python 3.11.2
                 git: not_in_PATH
          git commit: NA
                 tcl: 8.6
                  tk: 8.6
               glade: not_in_PATH

linuxcnc_var all:

     LINUXCNCVERSION: 2.9.4
LINUXCNC_AUX_GLADEVCP: /usr/share/linuxcnc/aux_gladevcp
LINUXCNC_AUX_EXAMPLES: /usr/share/linuxcnc/aux_examples
            REALTIME: /usr/lib/linuxcnc/realtime
                 RTS: /usr/realtime-5.4.290-rtai-amd64/bin/rtai-config
          HALLIB_DIR: /usr/share/linuxcnc/hallib
              PYTHON: /usr/bin/python3.11

dpkg -l '*linuxcnc*':
Desired=Unknown/Install/Remove/Purge/Hold
| Status=Not/Inst/Conf-files/Unpacked/halF-conf/Half-inst/trig-aWait/Trig-pend
|/ Err?=(none)/Reinst-required (Status,Err: uppercase=bad)
||/ Name            Version      Architecture Description
+++-===============-============-============-=============================================
ii  linuxcnc        1:2.9.4      amd64        motion controller for CNC machines and robots
un  linuxcnc-doc    <none>       <none>       (no description available)
un  linuxcnc-doc-en <none>       <none>       (no description available)
un  linuxcnc-sim    <none>       <none>       (no description available)
un  linuxcnc-uspace <none>       <none>       (no description available)


 

With a specific bios setting Linuxcnc does open and axis moving smooth, but at start up i get "unexpected realtime delay on task 1.

I would recommend your 7i76e option you mentioned in your first post.

Wheezy is far too old to expect stuff to still work. its well past end of life
Whilst the linuxcnc guys have done an amazing job keeping RTAI working for all these years its also past end of life.
Without the Linuxcnc devs, RTAI would not exist today.
Preempt_RT has won the real time wars.
If the default Linuxcnc ISO works reliably for you, it will work with a 7i76e

But like any modern OS, things are more complicated today and there are a number of optimisations I cover here
docs.google.com/document/d/1jeV_4VKzVmOI...diY/edit?usp=sharing
 

Yes, buying the 7i76e might be a good idea, but its difficult to get (out of stock everywhere) and i would wish to not need to rewire anything and configure.

Of course I could ask or look for a pc setup that works 100% with the newest rtai kernel and buy the same hardware, but its just strange that I cannot get that machine that worked really well with wheezy not working on debian 12.

On tomorrow i will try a couple more bios settings but all energy saving functions are disabled and I know I didn't had to fix so many things to get a jitter of about 8000.

@tommylight: this I have solved already and the machine sounds and works by jogging perfectly fine now, but I still get unexpected realtime error on task 1 on start up.

Currently I mostly do changes in the cpu ratio and other cpu settings like cpu bus frequency and if I setup a wrong value, lets say, cpu frequency 165 instead of 120 then the machine might make that strange movement, smooth but not all the time.

I attach 2 pictures of one windows screen (tweaker), so that you see the options. That are not anymore the current settings. Tomorrow I can show pictures of the other options available but I am sure it's setup correct.

In grub config I have only what was already there: "quiet" and I added "isolcpus=5" to it. I believe with wheezy I had isolcpus=1,2,34,5, but I am not sure anymore.
The cpu is a amd phenom ii x6 1055t.

The 7I76E has been replaced with the 7I76EU which is available from a couple of sources.
 
The 7I92T option would work with your existing breakouts, but it would require
completely different hal/ini files.

 

Thank you for that.

Update: I have the pc at this moment at home, so i can do some tests while doing my work.
When i start latency-histogram and run it for some time (e.g. 15 min) with 3x glxgears the base thread looks good. Depending on the cpu bios settings i have stable max us of 20.000, but i found out that when i addionally start a youtube video (720p), the latency goes up, pretty quickly, almost directly after starting the video and then the latency jumps to 45000 then 60.000 and who knows how high it goes but then of course it doesnt matter anymore. 
Of course i have to connect the pc back to the machine and see if it starts without unexpected real time delay and if the machines runs smooth, because after going from wheezy to debian 12 i had the situations where there latency-test (not histogram) showed good results in for a short time but the motors didnt move as they should.

While writing this post, the latency-histogram is still runing and still at 20.0 us. Maybe i am able to get it to work, but it seems that the vga might cause the latency spike and thats why i get a unexpected real time delay on start up.

What i could do next is to buy better ram, because one stick of the ddr3 1600mhz (2x4gb) ram that i had from my last main pc is not working, so i am currently using some old 1333mhz ddr3 2x2gb rams.
Also a onboard vga might give better results, but i dont have a pc with integrated vga to test it.

Update:
The machines works again, without unexpected real time delay and a very good latency, but i had to take the PC of my Lathe. (the lathe machine uses the Mesa 7i76e card)
That PC has a on-board graphic card, but i first tested it with the VGA that was already there and i got the same latency issues. As soon as i used the on-board vga, the latency was perfect and no "realtime errors" at start up.

I have started latency-histogram, with 4 x glxgears and a youtube video running for about 1 hour.
I first started the histogram, then opened one glxgears and waited to check if anything spikes happen. Then i opened 3 more glxgears. No latency spike. Then the youtube video and the pc was running like that for almost one hour without any change to the base thread.
On tomorrow i will run a milling program and check if anything bad happens.

Also i will connect that "latency issue PC" to the Lathe and hope there will be no problems, but i think with the Mesa card there shouldnt be any.