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I've just built the current 2.9 branch (ie 2.9.6) and tested "halui.machine.is-on" reacting to "halui.machine.on" and "halui.machine.is-off", works for me in both tested guis (axis, gmoccapy)

Thanks! I saw your post and started reading it. There's a lot there.

Were you able to replace the resolvers with encoders? Are they part of the motors?

I ask because I found a video of some guy who did a Nakamura LinuxCNC retrofit and he opened up the Fanuc spindle motor and replaced the Fanuc encoder with one he bought off of Alibaba. He had to machine a custom mount for the encoder.

I don't know if the resolver process is similar or if I have to buy all new servos.

I did a Mazak MS15
forum.linuxcnc.org/show-your-stuff/32784...-15-retrofit?start=0

can you please show us the parameters you used?
'loadrt classicladder_rt .....'

If you open one of the sim configs and check "halui.machine.is-on" does it go true when you enable the machine with the gui button?