I have been quite happily using the 2010 screenset on my Mach3 CNC router with a Cs-labs CSMIOIps controller. The biggest bonus was the automatic tool height/tool change facilty.  HAs worked fine for 6 years with no issue, only small niggle was using the mach3 pp from aspire would cause a double touch of during tool height measurement,  no big deal could live with that. Now all of a sudden, when trying to use the auto tool height / tool change I get PID error . This happens  when I use the double chevron button to measure initial tool height.  it touches down on the first block placed on material as per usual then moves across to the fixed plate and on it's first touch down I get the PId eror and message asking for controller reset. I have done a few searches and this appears to be a problem that happens but I cannot understand how it could happen so suddenly after 6 years of working fine, has worked through upgrades to windows from 7 to 10 no problem and all aspire versions no problem until now.  Frustrating and very very weird.

Sounds like a comms or feedback glitch between Mach3 and the CSMIO/IP-S. Try checking probe wiring and grounding, updating the CSMIO plugin/firmware, and lowering PID gains. Also test a manual probe from MDI to see if it’s motion-related. A plugin reinstall often clears this up.