Laser losing connection - now cut settings have gone haywire

I’ve been running into an error since yesterday “There was a problem sending data to the laser” - even though its been connected to USB. After a few restarts of both Lightburn and the laser (Thunder Laser Nova 24 60W), they finally reconnect, but…

Now my trusted cut setting for acrylic is burning through the material uncontrollably and melting edges. I’ve changed between a 2" and 1.5" lens to see if its a focus/lens problem and the cut is terrible on both.

I’m wondering if something in Lightburn needs to be reset for the cut settings to come back? You can see in the photo, the gold acrylic card is a sample I cut last night (crisp cuts). Now, the silver is cutting like it was done with a welding torch. Any thoughts?

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