ERROR: pierce height would exceed Z axis maximum limit

This is really strange and I have no idea how to resolve it.
As soon as Plasmac probes, it goes straight to max Z height and then generates this error:
Tried the Plasmac metric wrench and behaviour is unchanged.

I can't see any reason why in the settings. Bottom of travel is about 12mm below the material height so the probe and safe heights are valid. I am at a bit of a loss with this.

  

I have not changed anything and have done an upgrade in the last few days to no avail. Currently on V 1.221.156. It just happened one day when I started it. But I am unable to cut anything.

There was a window in time where an update would remove the following line from the machine hal file, if you add it back to the hal file it should be ok:

The joint number obviously needs to be the joint mapped to the Z axis.

Edit: Oops, I think I misread the warning...

Simply put it means that the probe is high enough that the torch won’t be able to move to pierce height without violating the soft limit.

Since it says it was found during ohmic testing, have you tried it without ohmic checked?  When I had THCAD ohmic, this was something I encountered.  It could be a false trip, perhaps there’s some dross on the tip giving a path through the electrode, etc.  

EDIT:  forgot about the thing Phill said, I’d check his suggestion first

 

Actually snowgoer got the prize!
I knew I bought new consumables for a reason!
The probe was shorted inside the tip so it was rushing away from the material to clear the probe signal.
Replacing the consumables solved the issue.

Thanks guys. Helpful to have other sets of eyes in the background!

Good deal, glad it was a simple fix