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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.