I'm having a bit of trouble getting automatic Z zeroing of a plasma cutter floating head to work. I'm using R3.043.066 with a CSMIO IP-S controller. The G31 probing works, but G92 keeps using/setting the wrong values.

For example, when using this program:
N0010 (Filename: ring 101x61.tap)
N0020 (Post processor: Mach3 flame with THC - G31.scpost)
N0030 (Date: 10/11/2022)
N0040 G21 (Units: Metric)
N0050 G53 G90 G40
N0060 F1
N0070 S500
N0080 (Part: ring 101x61)
N0090 (Process: Outside Offset, 0, T15: 10mm 100amp THC147)
N0100 M06 T15  (10mm 100amp THC147)
N0110 G00 X43.4600 Y28.4900 Z14.0000
N0120 G31 Z-100 F3750.0
N0130 G92 Z-0.0800
N0140 G00 Z10.0000
N0150 M03
N0160 G04 P0.3
N0170 G01 X43.4600 Y28.4900 Z6.8000 F3750
You can see that it first goes to Z14. Then the G31 probing happens. The Z axis stops when the proximity switch gives the right signal. But then G92 gets set to the current negative offset (Z moved down, -22.6 for example) + 14 (the Z height set earlier). The G92 Z offset becomes 22.6+14=36.6. The next command is G0 Z10, but the actual torch height is 36.6+10=46.6mm above the material. Why and how does this happen?

I have also tried G28.1 instead of G92. This works, but I have a lot of files with G92 which I then can't use anymore.

Have you checked the offset for tool 15, my guess is it should be zero.  It could also be you need a G4 P.25 before the G92 line

All the tool offsets are 0. I tried different G4 delays from 0.5 to 5 seconds, without any result.

I read somewhere that there could be a difference in calculations whether the machine is controlled by the PC or an external controller. The previous setup was with two 5-axis parallel port breakout boards, now we are using a CSMIO IP-S. Could it be that certain commands like G31 or G92 are processed internally on the CSMIO? I'm curious if I'm doing something wrong, or don't understand these G-codes, or that it could be a bug.

I think you need to ask CS-Labs about this one.

I asked CS-Labs, they replied that they haven't had any trouble using G92. They sent me an alternative macro, M20, for height measurement. I haven't used it yet, because we are now using G28.1 instead of G31. This works good.

But we now have a new problem. I created 3 custom macros: M200, M201 and M202. These are used for turning an electric drill on and of the dril is attached next to the torch on a different axis (A). M202 has the following code:
ActivateSignal(output2)
ActivateSignal(output3)

M200 is:
DeactivateSignal(output2)
DeactivateSignal(output3)

The outputs are set in Ports & pins to the CSMIO outputs that are connected to relays. The problem is that Mach3 pauses when M202 called in the G-code. It also pauses when a custom button in the interface is clicked. This button executes the same code as M202. The machine has to be paused/stopped and restarted to continue with the G-code. But the drill is then turned off. When executing G-code and manually turning the drill on and off (custom buttons in Mach3 interface using the same code as above), the machine also pauses when the drill is turned on and continues when the drill is turned off.

What can be the cause of this behaviour?

Example code, the machine pauses/stops on M202:
N0100 G00 X53.0000 Y-95.0000 Z14.0000
N0110 A14.0000
N0120 A5.0000
N0130 M202
N0140 G01 A-10.0000 F100.0
N0150 G00 A-5.0000
N0160 A-10.0000
N0170 G01 A-20.0000
N0180 G00 A-15.0000
N0190 A-20.0000
N0200 G01 A-30.0000
N0210 G00 A-25.0000
N0220 A-30.0000
N0230 G01 A-40.0000
N0240 G00 A-35.0000
N0250 A-40.0000
N0260 G01 A-50.0000
N0270 G00 A14.0000
N0280 M200
N0290 X65.0000 Y65.0000
N0300 X3.0000 Y-95.0000

Have you got a return on the end of the last line?

What/where do you mean?

The macro files M200, M201 and M201 have a blank line on the end. Example, "decoded":
/r/n
DeactivateSignal(output2)/r/n
DeactivateSignal(output3)/r/n


That should be good.

When you say it pauses is it for a fixed time or until you press Cycle start?

The stop and start buttons need to be pressed to continue. But this resets the outputs and switches the drill off.

Would you post your XML file for me to look at as I can find no real reason why this should happen.

BTW

Did you turn off 'Include TLO in Z from G31' in general config when you had the probe issue?