Chris,
The changes you made seem to be doing the trick. I was able to do a home all repeatedly with no errors, thanks a bunch.
I do still have one minor problem though. I am using the one button touch off mod and will get an error to the effect that it cannot jog when the probe is active. This happens when the probe is retracting from the touch plate. Touch off and zero offset works but rapid away will fail about as often as it is successful. It seems to be when the work piece is a bit flexible like thinner sheet steel when doing a plasma touch off. The material returns to normal shape when the z starts to retract and in doing so seems to hold the probe active long enough to trigger the error. Any suggestions? We're only talking about a few thousandths of deflection at most.
Dan