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Okay, I finally have the rtai version running, but I seem to only be able to run the latency-histogram as sudo.  Is that the way you're supposed to use the rtai version?

Some notes on the install, as the directions leave out specifics of a lot of steps.  (Half the words in 7.2.4 are separate steps without spelled out commands.)  Hopefully this helps some others.  I followed a lot of forum.linuxcnc.org/9-installing-linuxcnc...tall-rtai-got-errors

Also, I'm not sure if these were done in the correct order.

After installing from the live cd and booting into the new os, I ran

sudo apt-get update
sudo apt-get dist-upgrade

I'm not sure if I did this next, or it was somewhere else on the way.

sudo apt-get purge linuxcnc-uspace
sudo apt-get purge linuxcnc-doc*

Next I updated /etc/apt/sources.list.d/linuxcnc-uspace.list adding 2.9_rt to

deb [arch=amd64,arm64 signed-by=/etc/apt/trusted.gpg.d/linuxcnc.gpg.key.binary.gpg] www.linuxcnc.org/ bookworm base 2.9_uspace 2.9-rt
deb-src [arch=amd64,arm64 signed-by=/etc/apt/trusted.gpg.d/linuxcnc.gpg.key.binary.gpg] www.linuxcnc.org/ bookworm base 2.9_uspace 2.9-rt

(Note I think this is what the linuxcnc-install.sh script called out in the directions is supposed to do, but instead it adds a linuxcnc.list to the sources.list.d, which causes a conflict with what is in linuxcnc-uspace.list and means that apt and the Synaptic Manager stop working.)

Next I did another:

sudo apt-get update

Next I installed the real time kernel:

sudo apt-get linux-image-5.4.258-rtai-amd64

Note: You have to put in the version number. You can tab to find the right one to finish the line. It should have rtai.

REBOOT!!!! Here you have to reboot into the rtai kernel (I think). When the blue screen comes up press down to the second option to choose the rtai kernel.

Next I installed the modules and linuxcnc:

sudo apt-get install rtai-modules
sudo apt-get install linuxcnc

Here I don't think I needed the version number, but if you get an error you can try that.

I also installed headers at some point. I don't know if that was necessary:

sudo apt-get install linux-headers-5.4.258-rtai-amd64

I think I ran the linuxcnc install again after, but I don't know if it was necessary.

sudo apt-get install linuxcnc

The reward for all this... It looks like my min/max base thread latency is about the same as the preempt_rt version.
 
Any other ideas what to try?

Like I said it's the thread period that is limiting your speed.

This is so specific, I'm guessing I've got a bone-headed mistake.
I've attached my .ini and a couple of screenshots.
My machine lines are showing going to the back of the Y=0 line, not in front.
All my homing and jogging and machine movements are correct.
I do have GEOMETRY = X-YZBC, but the red machine lines are out the back of the machine if I turn that to XYZBC, and when I set it without the -Y, movement in the display is mirrored in Y
My Y home sensor is in the back, X to the left, and Z on top, so the machine is oriented:
Z: Top is zero, Down is Negative; X: Far Left is zero, right is positive; Y: Far Back is zero, forward is positive.

Can I keep those orientations and get the red lines to show around the actual working space?
The inconvenience here includes that the measurement lines are inside the machine space, but waaay back from where it's visualizing the program (the white spiral lines).
The white spiral lines are in the right place, but the measurement lines and the axis lines and the red machine outline are all backwards with respect to Y.

(I'm on linuxcnc-uspace 1:2.9.4, and QtDragon)
 

Yes, there is 7I97T firmware for running the common "Mach 5 Axis"
step/dir breakout board:

7i97t_5abobd.bin
 

Line 12,  M61 T0  should be
M61 Q0

You might still use it, if there is firmware that puts the stepgens on the IDC26 connector and use a cheap BOB to wire in the drives. Requires also an DB25 to IDC26 cable, so all cheap stuff, but be warned that cheap BOB might limit the step frequency a lot.
You can just wire drives directly to IDC26, but that does require caution in proper wiring as those I/O pins are highly sensitive. Having said that, i use those pins on plasma machines and never ever had any die.
But if you still want to get a new board, get the 7i96S as it can be found easily and can be expanded easily by adding, say a 7i84 for 32 more inputs and 16 more outputs, and say a 7i85 for more encoders and more boards like 7i84 or 7i70 or 7i71 or....

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.

 

Notice o053 in two instances above, so i am guessing they should be O upper case as the rest of them.

The T3D drive has an analog input option but no encoder output
(which is a bit uncommon) so will not work with the 7I97/7I97T.

A step/dir board would be required, a Mesa 7I96,7I96S or 7I76EU
are possibilities.

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.

Second shop from earlier:

And second shop from 9 months ago:

Last i checked, something that comes close to QtPlasmaC in functionality (not in usability by far, much harder to use) was over 170000$ with a 300A plasma source that costs 84000$, leaving the machine price at 86000$ for 6X2.5M cut envelope!
-
Here are some links that might help:
forum.linuxcnc.org/show-your-stuff/38547...-5m-cnc-plasma-build
forum.linuxcnc.org/show-your-stuff/48985...s-frequently-updated
forum.linuxcnc.org/show-your-stuff/35337...2m-work-area-or-12x7
forum.linuxcnc.org/show-your-stuff/35306-cnc-plasma-tube-cutter

Could someone help me find my error?
The program orients the spindle and calls an unknown control command in o word. I have attached the toolchange.ngc that is throwing the error.

I have T3D servo motors and a 7i97t board but it seems that it is not compatible. Which board would you recommend for 5 or 6 of these servo motors?