Hope someone can help me here.
I set up this plasma table a year or two back, then it has just recently started to operate incorrectly.

The torch will turn on and off using the torch on/off button and it will turn on and off if I type m03 and m05 into the bar.

But when a program runs, the torch remains lit all the time.

I assume I must have changed something in my config but can't see it. Then I used a backup config file and still the same.

The machine is a plasma cut table UC400eth motion controller. A simple relay turns the torch on and off. I think its connected to output 1.

I have attached my xml and an example of a file that is failing.

had a quick look to your example.

the only Thing i can see, that every M5 is followed of a M157.

do a quick test in MDI

M3
M05 M157

and post your M157.M1S macro file.

Thanks for looking. It seems that m157 has no effect.

had a look to your Profile,nothing Special, output1 is for torch control.

the macro 157 nly deactivates output2.

so take a backup off your Mach3 Folder, install a fresh copy of mach3 and
restore your licence, XML and macros and maybe screenset.

OK thanks for the recommendation I will try that.

I re installed Mach 3 and copied xml file and licence file, but still had same problem.

can you just for test add this code to your M5.M1S macro

DeactivateOutput(Output1)

and check the error history (button left lower Corner)

OK i'll try that

I have found the problem.

The 2T 4T switch on my plasma cutter has failed and is stuck in the 4T position.

This means that holding the 'trigger' for 10 seconds sets the machine to constant cut!!!!!!

Thank you for your time helping me, it has been very much appreciated.