Brian
Many thanks for trying to sort this.
I've never had a problem with the G91 G28 Z0.0 line or that program for going into the softlimits, the problem I had with that program was it warn me that I would exceed the softlimits but it never did, this was with versions D1.90.081 & D1.90.090, the later versions 1.90.093, 1.90.094 & RC2.0.a don't give me this warning even if they will exceed the softlimits.
When I go onto the softlimits is usually when I've got one tool longer than the rest of them and I call a line like this G43 H1 Z20. obviously it rapids straight up into the softlimit if the tool length is similar or larger than the Z work offset.
This is a test file I use to test the softlimits are working it's the same as the other one I posted a few days back but with a tool length offset also.
G0G54G90
G43H1Z-1.
X230.
Y150.
Z-60.
X0.
Y0.
Z-1.
M30
With my .xml if X, Y, Z, or H1 offsets are greater than 1 then the machine will go onto the softlimits, as I said earlier versions D1.90.081 & D1.90.090 when on to the softlimits but gave no warning if I did this but if I put a offset less than -1 in it would give me a warning but then not go onto the softlimits, it was like there was a minus missing in a formula somewhere.
The latest versions I can't get them to give me a warning what ever I do.
Cheers
Chris