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hey rodw is it ok to post the link of your youtube live view?

Yes, a sserial card can add real time 24V I/O I would suggest a 7I84U which
adds 16x 5 to 28V 500 mA sinking or sourcing outputs and 32x 5-28V inputs.

The sserial devices are RS-422 so do not allow more than one device
per interface. This so the remote interface is real time.

The 7I95T also supports Modbus devices (mainly for VFD use).
Modbus I/O devices are common and inexpensive but do suffer
from a couple issues:

1. They are not real time
2. The inexpensive I/O devices I have tested do not have watchdogs
so leave outputs stuck on after LinuxCNC exits or there is a fault.
 

Good find there. That should fix merging, but not when there is an incomplete circle and there comes a line.

More on the philosophy around this - I don't know enough of the background to this - but when in center punch mode, would it be ok to center punch the center of any circle segment? Doesn't have to be full circle, like the center of a fillet. I mean, you go into center punch mode deliberately and mark circles. The intention is to make a center punch for all marked circles/segments. So only that should be done, no straight lines or half circles or anything. It is only making spots while in center punch mode. If so, one should rearrange the code so separate out this action, mark the center of the circle segments and ignore everything else.

I wonder if this with Smoothing off should be in the description, the PDF where center punch is described.