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I used to compile EtherCAT by myself, but since the packages became available I just install them as described here by rodw.
I take it you have run latency-histogram and have the graph nicely inside say +-20 microseconds for the servo thread?

I tried that but maybe there is an issue with my w5500. Thanks great Cornholio

Thank you for your response.

I would like to know what versions of LinuxCNC and Ethercat you commonly use, respectively.
I will reinstall the system.

This info assumes a single NIC with a driect cable connection from the Host machine to the other device.
All the host needs is an IP address on the same subnet so 192.168.10.xx
DNS - not required (only used for accessing hosts via host names not needed for IP addresses)
GATEWAY - not required (only required when there is a second machine that has access to a network outside of the 192.168.10 network)
NETMASK - 255.255.255.0 or 192.168.10.0/24 (depending on how you are required to input this info)

I have jogging setup as well as I can now.
Had to NOT the two switch inputs that control rate, and also enable the quadrature counting as well as adjust the mux parameters.
What I notice now is that I have to be very careful turning the wheel.
If too fast, the counts are missed, and if I get the speed of the wheel just right the axis moves in reverse.
With the original 1982 control, this wasn't an issue.
I'm going to scope the signals to ensure they are clean, but wondered if there is a max counting rate on the 7i73 that I am exceeding?
Thanks

I misunderstood that. N430 G3 is the full but incomplete circle. It  ends at 9 o'clock and finishes the gap with a straight line N435 G1.
I wonder why fusion chose a line between S2 and E2 instead of a circle segment. Do you have the Tolerance in the Passes tab tightened down?

I kind of think that "Unmatched messages", that many, are related to the real-time performance, jitter, of that particular system.
If possible, it would be interesting to duplicate the good system's complete disk and run that on the bad system.