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Ah-ha! The 24V field power GND is not connected to earth ground, I was not sure that it should be. That probably explains it then.

Just weird that the machine ran fine for so long.

Thanks, I was getting frustrated with the constantly changing symptoms. I will connect those grounds tomorrow and test again.

The hal driver installation is easy, you need to open terminal navigate to the hal-driver directory and run ./install.sh

Sample hal configuration in the hal-driver/test_config directory

Precompiled .uf2 in the repository binary directory, you not need to rebuild the project if you want to use

Ack!! 40V is a real issue and indicates a grounding problem. This likely
what damaged the step/dir outputs (accidental contact to shield ground would do it)

I would verify that the drive frame grounds connect to earth ground and that the
7I76E ground (24V logic power ground) is also connected to earth ground.