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I think its unlikely that you would need so much DPLL pre-trigger so I don't think
increasinh this timr to 250 usec is going to help

I would check hm2_7i76e.0.packet-error-total to see if you have dropped any packets

You might try plotting the following error and perhaps tuning by adding a little
FF2 (say .0003 to start) to the PID loop (using the calibrate menu so you can do this live)

Also, I considered using the directions at: forum.linuxcnc.org/9-installing-linuxcnc...tall-rtai-got-errors

but when I look at the directory linuxcnc.org/dists/bookworm/2.9-rt/binary-amd64/

I don't see a 2.9.4 version, so I wonder if that is the source of the problems (or maybe just completely unrelated).