SOLVED - Suddenly, Probe Moves work only once then error

Running 2.8.4 Axis from the ISO

I am suddenly very lost and I expect it’s an active G-code issue but it’s beyond my ken.

I routinely run in the following fashion: a) Insert a tool; b) touch off tool with a basic probe routine; c) run G-code program from F360 and the LCNC pp. The program pauses with a dialog “Hit ok when ready” - I've just touched off the tool, so I hit ok and program runs; d) Insert new tool for next op., touch off, Rinse and Repeat. Doing this for years with various versions of LCNC. Worked fine earlier this week.

This week I tried letting F360 build a “program” where-in it combined multiple ops into the same g-code file as long as they ran the same tool. Worked fine.Then I tried letting F360 build a program with multiple tools expecting it would let me do the tool change. That didn’t really work. There was an M6 in the beginning of the program, but when it was time to change tools there was a T code and a pause; no M6. And of course I couldn’t run my little probe routine while paused.That’s the last time things were sane.

I stopped the program so I could touch off the tool, but get the error “G38.2 move finished without making contact”. There is no motion when I initiate the probe. After this, there is an active G-code G38.2. I have no idea how to clear it, or if it would matter if I did. M2/30 in MDI mode didn’t help. Axis is not paused (though there is an M0 active G-code). Using the LCNC “machine power” button (and re-homing…) doesn’t help. The only thing that works is quitting LCNC and re-starting.

Then it works exactly once per my initial routine. I touch off a tool fine. I run one op. It terminates correctly. I go to touch off the next tool - G38.2 finishes with no contact (there is no motion) error.

Active G-codes are (once things stop working):
G38.2, G17, G40, G21, G91, G94, G54, G49, G99, G64, G97, G91.1, G8, M5, M9, M48, M53, M0, F15, S0

FWIW, Axis doesn’t seem to like switching into MDI mode when the tab is changed anymore. You have to switch tabs AND issue a command. Of course my probe routine requires MDI mode. Happy to provide more info but I am so lost right now, I’m not sure what’s relevant. Not even sure where this should be posted:))

Thanks,
Ron

TL;DR: Prior g-code run had left G21 active after running a metric file, but the touch off/probe routines assumed imperial. Adding G20 to various subroutines remedied the issue.

The good news: seems LCNC detected what would have been a move exceeding travel limits and didn't crash. Bad news: if there was an error posted anywhere saying its was being commanded to make an illegal move, I couldn't find it (doesn't mean it's not in there somewhere).