TORCH HEIGHT PROBLEMS

[SAWMILL]

I am having trouble with I believe the soft limit settings IN MACH 3. I was getting error messages Home switch active. I have been playing with the settings, and have finally got the torch to drop down to the metal, and cut but It will not fully cut !4ga. My plasma is set correct along with voltage. Been cutting for weeks at these settings on same ga metal, no problems. Just started having problems with mach 3 error messages. X and W DRO stay red, but Z goes green and cannot get it to change back to red unless I reload Mach. machine came set up ready to run. Read every Mach manual and watched tons of tutorial, can't figure it out.
PLAMA ROUTE 4 X 4
HYPERTHERM 65

[SAWMILL]

I am learning every day. I still have a little DRO problem. But my main problem was my consumables were worn out.
Changed them and cut a full sheet with no problem. I feel dumb, but I'm happy now.

[pinfab]

I had a similiar issue but it was my torch consumables doing it... i changed them out and it cut great... hope this helps..

[plain ol Bill]

Sometimes changes in cut quality etc. change very slowly over time and we do not realize it until things get really noticable. I had never changed anything on my consumables except nozzles and electrodes. I was having some problems with 3/8 material and finally changed ALL my consumables and the problem went away. Time will creep up on you. I noticed one day recently my torch cut height seemed really close to the material (I generally don't watch the torch while cutting). After thinking about it for a few minutes it dawned on me I was using the wrong post processor in Sheetcam. I have one process that I use a really close cut height on with a seperate post processor and had never changed it back for steel.