Was cutting out a new job today and when it came time to rout out hinge holes the machine stopped with a "Invalid arc, check the dimensions again." error I have not changed hinge patterns in two years and I haven't changed anything with the 1/4" bit in the past month.
Problem solved, bit #1 is a 3/8" Vortex compression and this is the first time we used a bit that has been sharpened twice making the dia. .335 close to the hinge hole size so control nesting was selecting it instead of the normal 1/4" compression bit and that was throwing the error all we did was turn off interpolate on bit 1 and everything is working again.