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I got a new computer and had to re-install SMAK, the newer Anaconda has a version of setup tools incompatible seemingly (traceback yields an error in finding pkg_resources) - rolled back the setup tools using:pip install "setuptools<70" for setup 69.5.1 and then smak was able to start normally. The prior issues with numpy and pymca noted below seemed OK now, but of course be aware when installing there can be versioning incompatibilities...
Thanks Eleanor, no, my file names start with regular letters. Looks like the issue is that some of my step sizes were smaller than the default interpolation size. Turning off interpolation solved the problem, as did setting the interpolation smaller than my smallest energy steps.