Acr ok/Up/Down not working

This was way back so no idea if this got fixed or not, but this did not work for some very strange reason as it is a must when setting up such a system.
You can try running a cut or two with the torch off, see if that activates the LED's.
You can also use hal show to watch the input pins and check if they are correctly set in hal, the do some actual cuts.

The inputs below are only valid while cutting as mentioned in  this table : 
The reason is because while the inputs are from an external source, the PlasmaC component still takes the following into consideration before making torch height corrections:
THC enabled?
Torch on (meaning the component is actually commanding the plasmac.torch-on output TRUE)?
Ignore Arc OK enabled?
Mesh Mode enabled?
Velocity anti-dive (cornerlock) enabled and are you below the anti-dive velocity?
Did we reach a top or bottom limit?

If you are curious, the pertinent Mode 2 code controlling all of this is here .  The GUI indicators only turn on when led_down or led_up are TRUE (assuming the correct HAL connections are made between the component and the GUI, of course).

I think you did the pertinent test by seeing that the appropriate HAL pins light up in halshow, and ensuring the correct HAL connections have been made.  I dont know what you mean by a simulated cut, but if the torch was not on (plasmac.torch-on TRUE), then it would not have worked.

I am not sure I would call it strange, but you'll have to make some actual test cuts to see the indicators light up.