Just because you search to a line does not mean everything it has seen so far is active.
It may not have the proper Tool Length Offset for the commanded line.
Example: You turn a machine on. Z zero is that the quill is up. You do not call up a tool and a TLO. You go to a drill line where the command is to go .050 above the part. The quill is already up and at zero thus it cannot go up any further. Z axis alarm!
George
(Note: The opinions expressed in this post are my own and are not necessarily those of CNCzone and its management)