LinuxCNC installation + 7I96S

Please attach your hal and ini files rather than including the text in the message as the forum
software mangles it so badly that it's basically unreadable.

Note that it is suggested to use pncconf or MesaCT to create hal/ini files for a current mesa card

This is likely the source of your following error issues.

 

Sorry about that. I'm attaching the files. With PNCConf, I couldn't get a configuration that would even allow LinuxCNC to exit emergency mode.    

Yeah unfortunately that's not going to work.

Not sure what the EStop issue is. It  may be a LinuxCNC 2.9.4 bug,
but the easiest way forward is probably to make a pncconf
configuration (or MesaCT configuration) and if the is a EStop
logic bug, to find and fix it in the hal. file.

Another possibility is to update to 2.9.7 which is available now.
 

I have something to mention. By increasing the Stepgen value on the three axes (from 24 to 30 in maxvel and from 120 to 150 maxaccel) when moving the motors quickly with the arrow keys, it no longer disconnects as easily as before. Could that be the source of the problem? When attempting to create a new configuration with Pncconf, there is some data that I do not know how to configure.

They also mentioned something about ‘isolcpus’ and ‘cpuset’ since my processor is an Intel Core i5-12400 2.5 GHz (new generation) and it could be related to that.

Edit:   I get this error (see attached image) 

I have been advised to isolate a core. I believe my Intel has 6. I have done the following:

I think I have isolated a core correctly.  cat /proc/cmdline BOOT_IMAGE=/vmlinuz-6.1.0-30-rt-amd64 root=/dev/mapper/debian--vg-root ro quiet isolcpus=1

isolcpus=5

would be correct for a 6 core CPU