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It's not obvious what's wrong. Forget the 0x20xx SDOs, you are not using them, they are not mentioned in ethercat-conf.xml.

Let's look at the error message in syslogIf you look at the subindices that are listed, they agree with the documentation
 
(From teknic.com/files/downloads/ClearPath-EC_Software_Reference.pdf)
Some subindices ARE missing and I don't know why the EtherCAT master makes a big deal of that. If it needs that info or what?
I think the Invalid input configuration is a consequence of those errors but could be something else also.

Almost out of ideas, but there are two things you can try. Set configPDOS="false" or remove the option altogether.
If that doesn't help, increase debug level on the ethercat master to hopefully get some ideas on what's going wrong.for example, try to start linuxcnc and list the messages in syslog again.
Can you also show the content of sdo 0x60c2:1 and 0x60c2:2 (interpolation time) Use commandCompare with table in manual.
 

Hi  thankyou for your post.  Do you have any videos of it in action?

Clearpath should have good docs. Typically the CIA402 registers are > 6000. 
Its not a one size fits all.

There are quite a lot of optimisations required with the later kernels (Debian 12-13). I have documented them in a PDF file available here
erpx.au/shop/trixie-linuxcnc-debian-trix...tion-pdf-download-48
There is a nominal AUD $2.00 fee for this info... Sorry but it was the only way I had to store a file.
While it refers to Debian 13 Trixie, it also is applicable to Debian 12 Bookworm.

I will say that feedback from users I've received says 2 core PCs are marginal for Debian 12-13 but some have got them working with the optimisations I describe. I have never used < 4 core PC's

Hahaha I look stupid, I thought "our solar system" you meant the solar system, some kind of weird google translation. Not a solar inverter as mentioned later.

You have my permission to make as much fun at my expense as you feel necessary. I honestly feel I deserve it.

Sorry if you thought I was making fun of you. Please accept my apologies.

I'm thinking more it's a bad filter cap and a rough infeed from the 3phase fronius solar inverter. It does bump the voltage up.

I'd look at a component heating issue first. Maybe just below "bad things" when it's not sunny outside, and pushed over the edge when it's sunny outside.
TBH honest the sun is huge, like really huge current thinking has it at 99.8% of the TOTAL mass of the solar system, all the planets and sundry matter make up 0.2% of the solar system (and our sun isn't all that big). And whether it's sunny or not outside it's still fusing ~600 million tonnes of Hydrogen per second into ~596 million tonnes of helium, thus fusing continues (element by element) until all that is left is iron, then we die, and being twisted by magnetic fields and the rest. So basically it's always on, doing what the sun does best fussing atoms into other atoms, generating heat and all manner of electromagnetic radiation.

I'm pretty sure if the ripple was being caused by the solar system you'd be noticing many many more items playing up.

But if you really want to check on the cosmic microwave background grab an old CRT tv, turn it on and turn to a channel that has no terrestrial signal, it'll give a reasonable idea of the radiation around. That's what a small part of the static is.

Ripple should not make too much difference, you might plot the bus voltage in halscope
to see if there's anything suspicious.

It should be fixed in that version:

forum.linuxcnc.org/plasmac/53657-holes-3...iour?start=20#308841

But probably you should try updating.

I will try to make some time to have a play with your CAM code.

After many -many many hours of having problems with random following errors in finally have found something that links. 
so, when it's not sunny outside the voltage i read on the 8i20 card is 315v dc. When the sun is in full swing it reads 325v dc. This doesn't seem to relate to anything I know, but I have no errors when the sun isn't doing much,  and  plenty when it is, I'm thinking that there is probably some induced ripple from our solar system,  and the dodgy fanuc power supply im using probably has a bad cap. Any ideas ???

The above link/post does not fix the issue, so try thisStill needs those two lines from the middle of the above linked post.

Could we make this a sticky.

Fix for RPi-firmware errors see this post:
forum.linuxcnc.org/9-installing-linuxcnc...-64?start=110#290282

forum.linuxcnc.org/9-installing-linuxcnc...-64?start=110#290282

Has the fix.

On the 7I96S there are 4 MPG channels built in with any standard firmware
These use the isolated inputs 0..7 but do not interfere with normal input use.

The count pins on the isolated I/O are:

hm2_7i96s.0.inm.00.enc0-count
hm2_7i96s.0.inm.00.enc1-count
hm2_7i96s.0.inm.00.enc2-count
hm2_7i96s.0.inm.00.enc3-count

There is also 7I96S firmware that puts MPG encoders on P1:

7i96sd_mpgp1.bin

Its MPG encoder count pins on P1 are:

hm2_7i96s.0.inm.01.enc0-count
hm2_7i96s.0.inm.01.enc1-count
hm2_7i96s.0.inm.01.enc2-count
hm2_7i96s.0.inm.01.enc3-count

These are additional to the MPG inputs available on the isolated I/O

If you are using buttons/MPG on P1, the  7i96sd_mpgp1.bin
is probably the best as it also uses the INM module so has built-in
debounce on all inputs.

1. What Ethernet chip does the host PC have?

2. What is the result of running:

sudo chrt 99 ping -i .001 -q -c 60000 [fpga_card_ip_address]

[fpga_card_ip_address] = 10.10.10.10 or 192.168.1.121 depending on card setup

The command will run for 1 minute and print Ethernet timing statistics

I ask about the Ethernet chip type because more recent kernels have a Realtek driver
that has terrible real time performance and must typically be replaced by the DKMS
driver.