Homemade, cheap, plasma CNC

FWIW, this g-code file ran fine on my sim machine (imperial machine though), but without a backup of your config, it's impossible to simulate your machine.

To get a backup of your config, click "BACKUP CONFIG" in the parameters (or settings if your screen is 4:3) tab.  Upload the resulting file here.

I do see the message in your logfiles.
I made a sim of your config and the file runs without issue.

If you jog your Z axis until it gets to the bottom of travel, how far in mm is that below the top of the slats?


 

I have done a heap of testing and cannot work it out. With the config as you posted, with the safe height at 99mm I only see the warning if the material is around 61mm higher than the top of the slats.

In the most recent post you mention the first cut, does it only happen after the first probe?
 

Check for active offsets, there is a small green ball shape if there are any.

Man, this is strange... Sorry for the pile of questions but I can't really get my head around what is happening.

When you say 8.4mm do you mean when it is moving between cuts?
What is the Safe Height parameter when it does this?
Does changing the Safe Height parameter change thie 8.4mm to something else?
If you do Z axis MDI of say 20mm does it actually move 20mm?
If you set the Safe Height parameter to a low value like 20mm does it still give the warning?

RNJFAB wrote:

No green ball Tommy.
 

My dog has one ... oh that ball !
Did you zoom in on the 0,0,0 coordinates? It is small, very small.
Also i did check on one of my machines today while i was chasing a gremlin in the electronics, PlasmaC and QtPlasmaC will always have that green ball on all machines with limit switches and proper homing... soooo
Check the G code quick reference for offsets and cancel all of them, there are at least 2, maybe more, then do the "torch just under the slats" exercise again and touch off Z.
I am blindly hoping there is a tool offset active messing things up, otherwise i am out of ideas ... or am i ???
Can you upload a video on youtube with the normal use process, from start to ... when things mess up.