I moved from 2016 to 2023 (new employment) and the best fit alignment is not working as I would expected. For example I get an "Error in A1" trying my normal 6 dof (YZ, YZ, XZ) using 3 edge points on a common plane. If I use the 3 same three poin

I did this backwards as this is my first post in nexus.  Trying to use best fit for manual alignment.  I have 3 edge points and first tried how I would normally setup (YZ, YZ & XZ) and get the error in a1 pop up.  If I align all the dof (xyz, xyz & xyz) I don't get the error but the deviation is up to 2.5mm.  They should be zero. See below info.

M_PNT3     =FEAT/CONTACT/EDGE POINT/DEFAULT,CARTESIAN
            THEO/<194,10,0>,<1,0,0>,<0,0,1>
            ACTL/<244.629,-304.904,-716.044>,<1,0,0>,<0,0,1>
            TARG/<194,10,0>,<1,0,0>,<0,0,1>
            EDGE_REPORT=<0.0309851,0,-0.9995198>,SURFACE_REPORT=<0.0309851,0,-0.9995198>
            MEASURE ORDER=SURFACE
            SHOW FEATURE PARAMETERS=NO
            SHOW CONTACT PARAMETERS=YES
              DEPTH=1
              SAMPLE HITS=1,INIT SAMPLE HITS=1,SPACER=0,INDENT1=2
              AVOIDANCE MOVE=AFTER,DISTANCE AFTER=5,DIRECTION=ALONG FEATURE VECTOR
              ONERROR=NO
M_PNT2     =FEAT/CONTACT/EDGE POINT/DEFAULT,CARTESIAN
            THEO/<189,0,0>,<0,-1,0>,<0,0,1>
            ACTL/<236.983,-316.934,-716.032>,<-1,0,0>,<0,0,1>
            TARG/<189,0,0>,<0,-1,0>,<0,0,1>
            EDGE_REPORT=<0.0309851,0,-0.9995198>,SURFACE_REPORT=<0.0309851,0,-0.9995198>
            MEASURE ORDER=SURFACE
            SHOW FEATURE PARAMETERS=NO
            SHOW CONTACT PARAMETERS=YES
              DEPTH=1
              SAMPLE HITS=1,INIT SAMPLE HITS=1,SPACER=0,INDENT1=2
              AVOIDANCE MOVE=AFTER,DISTANCE AFTER=5,DIRECTION=ALONG FEATURE VECTOR
              ONERROR=NO
M_PNT1     =FEAT/CONTACT/EDGE POINT/DEFAULT,CARTESIAN
            THEO/<87.522,0,0>,<0,-1,0>,<0,0,1>
            ACTL/<139.4,-316.605,-715.996>,<-1,0,0>,<0,0,1>
            TARG/<87.522,0,0>,<0,-1,0>,<0,0,1>
            EDGE_REPORT=<0.0309851,0,-0.9995198>,SURFACE_REPORT=<0.0309851,0,-0.9995198>
            MEASURE ORDER=SURFACE
            SHOW FEATURE PARAMETERS=NO
            SHOW CONTACT PARAMETERS=YES
              DEPTH=1
              SAMPLE HITS=1,INIT SAMPLE HITS=1,SPACER=0,INDENT1=2
              AVOIDANCE MOVE=AFTER,DISTANCE AFTER=5,DIRECTION=ALONG FEATURE VECTOR
              ONERROR=NO
M_PLN_ZP   =FEAT/PLANE,CARTESIAN,TRIANGLE,NO,LEAST_SQR
            THEO/<156.841,3.333,0>,<0,0,1>
            ACTL/<207.004,-312.814,-716.024>,<0.0003661,0.0007905,0.9999996>
            CONSTR/PLANE,BF,M_PNT1,M_PNT2,M_PNT3,,
            OUTLIER_REMOVAL/OFF,3
            FILTER/OFF,WAVELENGTH=0
MAN_ALN    =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
              ALIGNMENT/BF3D,LEAST_SQR,CREATE WEIGHTS=NO,ROTANDTRANS,USE SCALING=NO,-445.586,-341.612,702.591,179.816,2.058,-179.527
              ITERATEANDREPIERCECAD=NO
              Deviation Threshold=0.01
              SHOWALLINPUTS=YES,SHOWALLPARAMS=YES
                ID=M_PNT1,Points,,1,YES,NO,YES,YES
                ID=M_PNT2,Points,,1,YES,NO,YES,YES
                ID=M_PNT3,Points,,1,YES,YES,NO,YES
                ID=
            ALIGNMENT/END

Try changing measure order to both. It worked just fine for me.

PART NAME  : delete
REV NUMBER : 
SER NUMBER : 
STATS COUNT : 1
GD&T STANDARD : ASME Y14.5 - 2009/2018
 
STARTUP    =ALIGNMENT/START,RECALL:USE_PART_SETUP,LIST=YES
            ALIGNMENT/END
            MODE/MANUAL
            FORMAT/TEXT,OPTIONS, , , , ;NOM,MEAS,TOL,DEV,OUTTOL, , 
            LOADPROBE/4WAY_30X2_STAR
            TIP/T1A0B0, SHANKIJK=0, 0, 1, ANGLE=0
PNT1       =FEAT/CONTACT/EDGE POINT/DEFAULT,CARTESIAN
            THEO/<4.625,2.7747,0.95>,<0,0,1>,<1,0,0>
            ACTL/<12.4839,1.0726,0.95>,<0,0,1>,<1,0,0>
            TARG/<4.625,2.7747,0.95>,<0,0,1>,<1,0,0>
            MEASURE ORDER=BOTH
            SHOW FEATURE PARAMETERS=YES
              VOID DETECTION=NO
              SURFACE1=THICKNESS_NONE,0
              SURFACE2=THICKNESS_NONE,0
              MEASURE MODE=NOMINALS
              RMEAS=NONE,NONE,NONE
              AUTO WRIST=NO
              GRAPHICAL ANALYSIS=NO
              FEATURE LOCATOR=NO,NO,""
            SHOW CONTACT PARAMETERS=YES
              DEPTH=0
              SAMPLE HITS=1,SPACER=0,INDENT1=0
              AVOIDANCE MOVE=BOTH,DISTANCE BEFORE=0.3937,DISTANCE AFTER=0.3937,DIRECTION=ALONG FEATURE VECTOR
              ONERROR=NO
PNT2       =FEAT/CONTACT/EDGE POINT/DEFAULT,CARTESIAN
            THEO/<-2.1729,1.375,0.95>,<0,0,1>,<0,-1,0>
            ACTL/<5.7464,-0.2665,0.95>,<0,0,1>,<0,-1,0>
            TARG/<-2.1729,1.375,0.95>,<0,0,1>,<0,-1,0>
            MEASURE ORDER=BOTH
            SHOW FEATURE PARAMETERS=YES
              VOID DETECTION=NO
              SURFACE1=THICKNESS_NONE,0
              SURFACE2=THICKNESS_NONE,0
              MEASURE MODE=NOMINALS
              RMEAS=NONE,NONE,NONE
              AUTO WRIST=NO
              GRAPHICAL ANALYSIS=NO
              FEATURE LOCATOR=NO,NO,""
            SHOW CONTACT PARAMETERS=YES
              DEPTH=0
              SAMPLE HITS=1,SPACER=0,INDENT1=0
              AVOIDANCE MOVE=BOTH,DISTANCE BEFORE=0.3937,DISTANCE AFTER=0.3937,DIRECTION=ALONG FEATURE VECTOR
              ONERROR=NO
PNT3       =FEAT/CONTACT/EDGE POINT/DEFAULT,CARTESIAN
            THEO/<2.3332,1.375,0.95>,<0,0,1>,<0,-1,0>
            ACTL/<10.338,-0.2673,0.95>,<0,0,1>,<0,-1,0>
            TARG/<2.3332,1.375,0.95>,<0,0,1>,<0,-1,0>
            MEASURE ORDER=BOTH
            SHOW FEATURE PARAMETERS=YES
              VOID DETECTION=NO
              SURFACE1=THICKNESS_NONE,0
              SURFACE2=THICKNESS_NONE,0
              MEASURE MODE=NOMINALS
              RMEAS=NONE,NONE,NONE
              AUTO WRIST=NO
              GRAPHICAL ANALYSIS=NO
              FEATURE LOCATOR=NO,NO,""
            SHOW CONTACT PARAMETERS=YES
              DEPTH=0
              SAMPLE HITS=1,SPACER=0,INDENT1=0
              AVOIDANCE MOVE=BOTH,DISTANCE BEFORE=0.3937,DISTANCE AFTER=0.3937,DIRECTION=ALONG FEATURE VECTOR
              ONERROR=NO
ALIGN_1    =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
              ALIGNMENT/BF3D,LEAST_SQR,CREATE WEIGHTS=NO,ROTANDTRANS,USE SCALING=NO,7.8585,-1.6419,0,-0.0094,0,0
              ITERATEANDREPIERCECAD=NO
              Deviation Threshold=0.01
              SHOWALLINPUTS=YES,SHOWALLPARAMS=YES
                ID=PNT1,Points,,1,YES,YES,NO,YES
                ID=PNT2,Points,,1,YES,NO,YES,YES
                ID=PNT3,Points,,1,YES,NO,YES,YES
                ID=
            ALIGNMENT/END
DIM 1= LOCATION OF POINT PNT1  UNITS=IN ,$
GRAPH=OFF  TEXT=OFF  MULT=10.00  OUTPUT=BOTH  HALF ANGLE=NO
X       4.6250     4.6250     0.0000     0.0000     0.0000     0.0000
Z       0.9500     0.9500     0.0000     0.0000     0.0000     0.0000
T       0.0000     0.0000     0.0000     0.0000     0.0000     0.0000
END OF DIMENSION 1
DIM 2= LOCATION OF POINT PNT2  UNITS=IN ,$
GRAPH=OFF  TEXT=OFF  MULT=10.00  OUTPUT=BOTH  HALF ANGLE=NO
Y       1.3750     1.3750     0.0000     0.0000     0.0000     0.0000
Z       0.9500     0.9500     0.0000     0.0000     0.0000     0.0000
T       0.0000     0.0000     0.0000     0.0000     0.0000     0.0000
END OF DIMENSION 2
DIM 3= LOCATION OF POINT PNT3  UNITS=IN ,$
GRAPH=OFF  TEXT=OFF  MULT=10.00  OUTPUT=BOTH  HALF ANGLE=NO
Y       1.3750     1.3750     0.0000     0.0000     0.0000     0.0000
Z       0.9500     0.9500     0.0000     0.0000     0.0000     0.0000
T       0.0000     0.0000     0.0000     0.0000     0.0000     0.0000
END OF DIMENSION 3

I will in the morning but I think its something global as I have this issue with the last couple of programs I have had my hands on since I started.  I am having this issue on all of them as I am rewriting programs due to a fixturing system they have here. Plus I am using flow control to bypass the manual.  It had always gotten me real close and I have been doing this way for over 10 years. Not all my parts are square to the world so I use this instead of offsetting features to create the 321 features needed for that route.