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First of all, my deepest deepest sympathies,sorry to hear you live in Melbourne, the only good thing Victoria has to other is Philip Island and the roads, airports and docks that lead out of the state.

Why aren't you using the premade image for your RPi ?

The links are on the Linuxcnc home page under downloads.

Please supply config files.

No the W5500 works, initiating (ip addrr and other such stuff) is done via the FPGA via the SPI interface.
You'll have to setup your config to use the W5500 so that the correct bitfile is generated.

Examples and docs are supplied on the github project page.

Remember "it doesn't" work isn't very helpful when trying to get help. Config files and such help. Remember this is not a trip to the dentist, we are not dentists and don't want to have to pull teeth to get information to help.

What does that exactly mean? How do you initiate the w5500?

Any reason for not using the ready made debs from the releases page?
github.com/NTULINUX/RTAI/releases
Or from here
linuxcnc.org/dists/bookworm/base/binary-amd64/
and the corresponding LinuxCNC build from here
linuxcnc.org/dists/bookworm/2.9-rt/binary-amd64/

I think I'm going to send it, because I found in the /usr/src/RTAI/ksrc/5.4.279 there are 4 .patch files that I think are what I needed.

Yeah, to many things missing and/or wrong there, or wrong config files.
Use StepConf wizard to make a new config and choose as shown in the attached picture:

This wouldn't happen to be what you are saying is it?

$ git clone /ksrc/patches/v5.4.279/"*.patch ; do patch -p1 < "${i}" ; done

So, now that I finally found time and access to a pc, I can share my .hal and .ini

I really appreciate any effort anyone puts into this.

Resolved issues by installing via dpkg from the Linuxcnc Downloads page rather than the Synaptic packages, ie followed the instructions above!

Max jitter on Dell Optiplex 980 i3 550 3.2GHz, 16GB ram, 512GB SSD, has dropped from c.60,000 using preemt rt to c.9800 using rtai with everything recommended disabled in BIOS.

So a good result.

To be honest I'm still not sure what to do.

Currently I have no probescreen added to gmoccapy. I searched for a screen and just found topics about probescreen which requires a probe with electrical contact to the probe input pin. 

I do not have a probe like this. I just a simple probe with a 10mm probeball where a light flashes by contact or a simple 3d probe with analog measurementvalue. 

Is there any option to deal with? Simply probing an edge is not that problem. But how should I find the piece zero inside a hole?! Could you give me some tips? Maybe there is still an easy way to find the center of a hole... This is my main problem for now. 

Could I have some type of issue with the comms and data is getting corrupt?

No, modbus uses a crc checksum (ie the last two bytes of the messages). If your request got corrupted the crc would be wrong and the vfd would then ignore the request and you would not receive any response.

MAYBE the actrual issue here is the register to say enable spindle is the incorrect register in my drive, so the response is illegal data address?

Note that it says that it is 'reading setup parameters:' which fails. Enabling the spindle would not be a read function.

Is it odd that there is only 6 bytes received then a time out occurs?

The component does not handle exception responses (which are only 5 bytes), I guess.

I'm afraid I cannot help much more as I have no information about the vfd or the setup values for the component.

mBender wrote:

 with a W5500
 

I tried W5500 without success.
This module is not programmable and always requires initiation after the power turned on.
You need a programmable module that remembers the settings.
I suggest WT32-ETH01 (tested, and cheapest on Aliexpress).