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I'm not only a newby, but also a stupid one. You triggered me with asking for hal and ini file.
Initially I got an error on loadrt in my hal file. Then I ran the halcmd loadrt command (in a terminal without linuxcnc running) giving the specific error initially reported. Unfortunately these two errors had nothing to do with eachother. The error reported by the hal load was caused by my issue having no rights at the user/lib/linuxcnc/modules directory (so the modcompile went wrong).
After correcting the rights issue with the help of PCW, I executed the loadrt command without linuxcnc running.

So now loadrt mb25ioc32 ports=hm2_7i96s.0.pktuart.0 works fine and I see the pins with hall show.

At addf mb25ioc32 I now get the message:

corne@linuxcnc:~$ halcmd addf mb25ioc32 servo-thread
HAL: ERROR: function 'mb25ioc32' not found
<commandline>:0: addf failed


To be sure not making more stupid errors:
I run a out of the box config made with Linuxcnc stepconf
PC is connected to a 7i96s Mesa card with a nice pint (0.12 ms average)
Mesa card is on my desk and only connected with RJ45 and power.

Personally I wouldn't install to a USB drive. Far too many reasons to list.

One thing you have to be absolutely sure is that you are loading the boot loader to the correct USB device.

But if you do want to pursue it, the Debian forums would be the best place to look, as Linuxcnc is just plain old Debian bookworm with a real time kernel and the Linuxcnc app suite installed.

yes everything worked out! Thank you!

What PC?????????????
Realtek is the network card, and it will be enabled automatically if no boot devices are found.
In BIOS:
-disable secure boot
-disable TPM
-enable CSM
-enable compatibility mode
And as a general rule, don't look for answers on google anymore, it is useless mostly. Look at the coresponding forums, for Debian = Debian forums, for Mint = Mint forums, etc.

Tried every net solution for days to install linuxcnc, Debian, mint... nothing works. I did get as far as completing the installation successfully a few times, only to have my clean 1TB usb hard drive not be “found” on reboot. Also not showing up in bios “UEFI Boot sources” but the drive is first under bios setup “boot order” The live versions work but not any of the installs. Tried every possible bios setting and disk partition suggestions on the net with no luck. One odd thing that may help find the problem is that “UEFI: IPv4 Realtex PCIe FE family controller” and “UEFI: IPv6 Realtex PCIe FE family controller” keep showing up even after being disabled in “boot order” bios settings. I thought realtex was just for my old HP windows 8 audio system. Even after disabling everything but the USB drive in the boot order bios, the USB drive with the OS is not found. Since the internet came out and after all the OS systems I have installed, Linux OS seems impossible to install. Some Linux user must know what the problem is, but not any I found on the net offering solutions so far have worked.Correction… I misspelled “Realtex” it is “Realtek” 
 

Ethercat Update Sun, 16th Feb 2025

Ethercat installs and kernel modules build, some will build for running kernel, some build for 6.1.x kernel, but load with just a message about tainting kernel in logs. Just need someone with Ethercat hardware to confirm operation.

OK that's a good start, all we need is someone to confirm with actual hardware.