I just transitioned from Windows to Mac, new download, and get the same error. 
The default Raspbian OS now installed just fine on the same SD with the same 
equipment. I now dare to conclude that the problem is with your image.

Best,
Steffen

>
> Rod,
> 
> You referenced the download page and so I just went through 
> https://linuxcnc.org/downloads/ again and liked it a lot. Very clear, many 
> thanks! Whoever wrote that - many thanks! My initial reflex was like "Our 
> documentation should be as good or better" and then thought that maybe the 
> documentation should in contrary just depend on the download page to know 
> best what to download and we should possibly even minimize our LinuxCNC 
> documentation on OS install questions with a pointer to the Download page?!?
> 
> I downloaded the RPi5 image , ran xz -dt on it with no complaint, but then 
> got a complaint by rpi-imager, the image size would not be a multiple of 512. 
> That was with the same SD that had held the previous version. Did anybody 
> else get that message, too?  I ran this with another machine, with a USB SD 
> adapter, so something could be off. Will try another download and another 
> machine, but should someone else run into this, please kindly shout out.
> 
> Happy New Year to everyone,
> Steffen
> 
> 
> 
> > Gesendet: Sonntag, 31. Dezember 2023 um 20:06 Uhr
> > Von: "Rod Webster" <r...@vehiclemods.net.au>
> > An: "EMC developers" <emc-developers@lists.sourceforge.net>
> > Betreff: Re: [Emc-developers] RPi5 + Raspbian + LinuxCNC latency tests - 
> > first impressions
> >
> > Hi guys,
> > I've sent new images for the Pi 4b and Pi 5 to Andy for testing, with a
> > view that they be deployed on the downloads page. These both use the 6.1.69
> > kernel which is the very first version where the Raspberry Kernel and the
> > PREEMPT_RT patch align perfectly. Hopefully over the last 6 weeks, the pi5
> > is better supported now.
> > 
> > *Raspberry Pi 4b/400*
> > https://drive.google.com/file/d/1Bzx_PqRqdJVTMPlNMEG7z_RjJHf7QcDX/view?usp=sharing
> > 
> > *Raspberry PI 5*
> > https://drive.google.com/file/d/1HBXliMQE-OvU0PQPYEOK3OqJz0-CTO5K/view?usp=sharing
> > 
> > For initial login credentials, and initial configuration,  please refer to
> > the download page
> > https://linuxcnc.org/downloads/
> > 
> > Rod Webster
> > *1300 896 832*
> > +61 435 765 611
> > Vehicle Modifications Network
> > www.vehiclemods.net.au
> > 
> > 
> > On Sun, 31 Dec 2023 at 01:35, Steffen Möller via Emc-developers <
> > emc-developers@lists.sourceforge.net> wrote:
> > 
> > > Rod,
> > >
> > > Thank you for your kind and swift reply.
> > > HDMI sound works perfectly with the Raspbian default. Also, I think this
> > > would find quite some user base, since anyone reusing an old TV or a
> > > feature-rich monitor with the RPi would immediately benefit. I also
> > > mentioned games before :)
> > >
> > > The RPi image we come up with does not need to be perfect. Our users
> > > should just not be surprised with anythin when using it. My wishlist would
> > > be
> > >  * A pointer to our manual at all the places where the image could be
> > > downloaded
> > >  * The manual describing
> > >    - how the image is created so they can contribute
> > >    - what not to do with that image
> > >
> > > On a sidenote, please have a look at http://raspi.debian.net/. Nothing on
> > > the RPi5, though maybe this resonates somehow with what we are after.
> > >
> > > Best,
> > > Steffen
> > >
> > > > Gesendet: Samstag, 30. Dezember 2023 um 14:16 Uhr
> > > > Von: "Rod Webster" <r...@vehiclemods.net.au>
> > > > An: "EMC developers" <emc-developers@lists.sourceforge.net>
> > > > Betreff: Re: [Emc-developers] RPi5 + Raspbian + LinuxCNC latency tests -
> > > first impressions
> > > >
> > > > Steffen,
> > > >
> > > > Some good feedback thanks.
> > > > I'm really not surprised things broke on an update because we compile 
> > > > the
> > > > kernel from the Raspberry sources at a specific point in the commit 
> > > > tree.
> > > > It's not a generic  Debian build by any means. LIkewise installing a
> > > > different desktop is also asking for trouble.
> > > >
> > > > Having no sound is also not surprising because in the absence of an 
> > > > audio
> > > > jack you are dependent on HDMI and I know other SBC's have issues with
> > > HDMI
> > > > sound. If someone has a solution please let me know
> > > >
> > > > Please bear in mind that this image is over 6 weeks old and there have
> > > been
> > > > several kernel releases and countless commits to the raspberry pi kernel
> > > > since then.
> > > >
> > > > But for me, the main thing is that it's only in the last few days that
> > > the
> > > > kernel version and the PREEMPT_RT patch align perfectly so I am hoping 
> > > > my
> > > > next version is more robust. That has never happened in the life of the
> > > pi5
> > > > before.
> > > >
> > > > To test latency on the console, you can install the debian rt-tests
> > > > package. I have found that our latency-histogram yields similar results.
> > > >
> > > > I don't think a single 400 usec spike when opening a browser is of
> > > concern.
> > > > Thats not something you do when running a gcode program.
> > > >
> > > > Hopefully I will have some peace and quiet over the weekend to build a
> > > new
> > > > version.
> > > >
> > > > Rod Webster
> > > > *1300 896 832*
> > > > +61 435 765 611
> > > > Vehicle Modifications Network
> > > > www.vehiclemods.net.au
> > > >
> > > >
> > > > On Sat, 30 Dec 2023 at 21:58, Steffen Möller via Emc-developers <
> > > > emc-developers@lists.sourceforge.net> wrote:
> > > >
> > > > > Heya,
> > > > >
> > > > > Not only that we have a RPi4/5 confusion, you managed to add a Rod/b
> > > one.
> > > > >
> > > > > So, the image Andy pointed to (which I understand has its roots with
> > > Rod)
> > > > > works very nicely. While idle latencies did not exceed 12µs, mostly
> > > below
> > > > > 10. That was truly impressive. Once I got wifi up and initiated some
> > > > > downloads, it doubled to 24µs, much like the value Andy got. When I
> > > started
> > > > > up firefox and selected youtube, I got a single value of 400µs, 
> > > > > though.
> > > > >
> > > > > A complaint I have is that there was no sound in the default
> > > installation.
> > > > > The 400µs I like to speculate may be associated with the failed
> > > attempt to
> > > > > perform the respective initialisations.
> > > > >
> > > > > Another complaint is that the image is not stable when it comes to
> > > > > updates. I was curious on the effect that the installation of KDE 
> > > > > would
> > > > > have on the latencies, and if the missing sound would install with it.
> > > So I
> > > > > installed the package "task-desktop-kde" with debfoster. That ruined
> > > the
> > > > > reboot since the expected kernel image was no longer found. I made a
> > > > > screenshot with my phone and send it to whoever is interested, but my
> > > hunch
> > > > > is that Rod's new image if depending more on Debian's installation 
> > > > > will
> > > > > likely solve such inconsistency issues.
> > > > >
> > > > > Do we have any latency tools that would run without X, so we get a
> > > > > baseline of what software layer is costing us how much? I recall that
> > > we do
> > > > > but latency-test at least does not. I am asking since the
> > > latency-sensitive
> > > > > gaming industry should have some strong incentive to look into what we
> > > are
> > > > > doing but I have not seen too much from them, yet. Ok - this may be
> > > > > something for another thread.
> > > > >
> > > > > Best,
> > > > > Steffen
> > > > >
> > > > >
> > > > > > Gesendet: Samstag, 30. Dezember 2023 um 04:15 Uhr
> > > > > > Von: "Rob M" <ozzyro...@gmail.com>
> > > > > > An: "EMC developers" <emc-developers@lists.sourceforge.net>
> > > > > > Betreff: Re: [Emc-developers] RPi5 + Raspbian + LinuxCNC latency
> > > tests -
> > > > > first impressions
> > > > > >
> > > > > > Umm Rod Old Mate was referring to the my linked images for the RPi4,
> > > not
> > > > > > your ones, the ones I built for other reasons.
> > > > > >
> > > > > > On Sat, Dec 30, 2023 at 1:26 PM Rod Webster <r...@vehiclemods.net.au
> > > >
> > > > > wrote:
> > > > > >
> > > > > > > >None of those images were for the Rpi-5, I thought the RPi4 in 
> > > > > > > >the
> > > > > file
> > > > > > >
> > > > > > > Well yes they are. Andy and Steffan are using pi5 variant of my
> > > image
> > > > > which
> > > > > > > is used for the 2.9.1 release from here:
> > > > > > >
> > > > > > >
> > > > >
> > > https://drive.google.com/file/d/1H_q0Ra-27ZDOhquvq179beUZQNVlex1f/view?usp=sharing
> > > > > > > Filename (with rpi-5 in it):
> > > > > > > rpi-5-debian-bookworm-6.1.61-rt15-arm64-ext4-2023-11-17-1520.img.xz
> > > > > > > It was built for the Pi 5's BCM2712 board.
> > > > > > > Username: cnc Password: cnc
> > > > > > > to finalise the installation (wifi, password , locale etc) type:
> > > sudo
> > > > > > > menu-config
> > > > > > >
> > > > > > > If the  screen resolution is not right, it should be able to be
> > > fixed
> > > > > with
> > > > > > > a parameter in one of the pi's config files.
> > > > > > >
> > > > > > > I have just completed and tested a 2.9.2 installer for X86 on
> > > Debian
> > > > > 12.4.
> > > > > > > I managed to bypass the raspberry-firmware installation bug in
> > > earlier
> > > > > > > versions (Inherited from Debian)
> > > > > > >
> > > > > > >
> > > > >
> > > https://drive.google.com/file/d/1nw0dGt5aZXVo8k68lLf4N_nzc0wTczAg/view?usp=sharing
> > > > > > > I will also rebuild the images for the Pi4 and Pi5, but I am
> > > kernelled
> > > > > out
> > > > > > > for today!
> > > > > > >
> > > > > > > Rod Webster
> > > > > > > *1300 896 832*
> > > > > > > +61 435 765 611
> > > > > > > Vehicle Modifications Network
> > > > > > > www.vehiclemods.net.au
> > > > > > >
> > > > > > >
> > > > > > > On Sat, 30 Dec 2023 at 12:00, Rob M <ozzyro...@gmail.com> wrote:
> > > > > > >
> > > > > > > > None of those images were for the Rpi-5, I thought the RPi4 in
> > > the
> > > > > file
> > > > > > > > name would made the obvious, but as this a topic about the 4 I
> > > guess
> > > > > > > there
> > > > > > > > could be some confusion.
> > > > > > > >
> > > > > > > > As for the recent RPi5 image you tried does that have any issues
> > > with
> > > > > > > > screen resolution? Is it stuck on a single resolution? Does it
> > > > > detect the
> > > > > > > > display it's attached to ? These issues, as mentioned
> > > previously, a
> > > > > game
> > > > > > > > stopper for myself.  If they aren't an issue could you say what
> > > > > > > > kind-brand-model display you're using ?
> > > > > > > >
> > > > > > > >
> > > > > > > >
> > > > > > > >
> > > > > > > >
> > > > > > > > On Sat, 30 Dec 2023, 11:40 andy pugh, <bodge...@gmail.com>
> > > wrote:
> > > > > > > >
> > > > > > > > > On Sat, 30 Dec 2023 at 00:27, Steffen Möller via 
> > > > > > > > > Emc-developers
> > > > > > > > > <emc-developers@lists.sourceforge.net> wrote:
> > > > > > > > >
> > > > > > > > > > Andy's image was a success - I just did not know the
> > > passwords.
> > > > > > > > >
> > > > > > > > > I mentioned it in a previous message, but it is cnc / cnc
> > > > > > > > >
> > > > > > > > > --
> > > > > > > > > atp
> > > > > > > > > "A motorcycle is a bicycle with a pandemonium attachment and 
> > > > > > > > > is
> > > > > > > > > designed for the especial use of mechanical geniuses,
> > > daredevils
> > > > > and
> > > > > > > > > lunatics."
> > > > > > > > > — George Fitch, Atlanta Constitution Newspaper, 1912
> > > > > > > > >
> > > > > > > > >
> > > > > > > > > _______________________________________________
> > > > > > > > > Emc-developers mailing list
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> > > > > > > > >
> > > > > > > >
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