2.9.3 - Stuck in wrong state and stops

Attached is the clients full config. 
As I thought, runstep.hal is not loaded in the .INI file (ie commented out) so keep looking!

It is appreciated. image missing /media/kunena/emoticons/cool.png

I made a sim from your config and after lots of testing I was unable to replicate the issue.
It should be noted that I did not test pendant, ohmic, or step boost, I commented these out and also replaced my_Plasma.hal with sim_no_stepgen.tcl which is the standard QtPlasmaC sim hal file. I am only able to test in a sim as I have no hardware. If you can replicate it in a sim then could you post the sim and the workflow that causes it.

I did note that in showstopper.ini the relationship between the MAX_VELOCITY and MAX_ACCELERATION settings for the X, Y, and A axes and  their corresponding joints are incorrect.
 

Thanks for trying. The hal files you bypassed are all well tested and are all for specific hardware so you could not implement them.

When you say that the velocity and acceleration is incorrect, I think you are expecting to see the axes values higher than the joints to allow for external offset ratio. But in practice, that is not necessary. I have them set as I always have since before external offsets was pushed to master 7-8 years ago.  After all, I was the one who worked out that we can double velocity and acceleration and use a 0.5 ratio because THC is mutually exclusive with gcode motion. The author of external offsets had not thought of this at the time. This was a major discovery that enabled THC control and ultimately qtplasmac without compromising velocity and acceleration.

I might add that there were a lot of constraints due to the machine design that we retrofitted with showstopper but the owner is happy as one job that took 2 hours now only takes 20 minutes because of QTplasmac.

Its little things like this that prevents him walking away from the machine on his lunch break! Hopefully, we will find a solution one day.

How self-righteous must one be to ask the component creator for help, only to turn around and explain why he's wrong? You’re always quick to highlight your own contributions; maybe it's worth pausing to genuinely consider the input provided.

In addition to what Phill said, when I looked at the config, I noticed that JOINT_3 STEPGEN_MAXVEL is not set to the recommended value of 25% larger than MAX_VELOCITY. Instead it's set only 4.16% greater than MAX_VELOCITY.

For Joints 0, 1, 2, STEPGEN_MAXACCEL is 50% greater than MAX_ACCELERATION (recommended is 25%).
For Joint 3 STEPGEN_MAXACCEL is 87.5% greater than MAX_ACCELERATION (recommended is 25%).

To highlight Joint 3 (the joint associated with the axis you're having trouble with) inconsistencies:

• STEPGEN_MAXVEL is only ~4% greater than MAX_VELOCITY
• STEPGEN_MAXACCEL is 87.5% greater than MAX_ACCELERATION

These inconsistencies stand out, and regardless of how long you’ve been using these settings, the values for both the axes and joints are still not aligned with best practices/recommendations. It's difficult to predict the exact repercussions because, generally speaking, most configurations follow these minimum recommendations. Yours is definitely the outlier.