Qtdragon_hd Zero button not zeroing

Initialling I was thinking this was simply rounding error, but I think it is something else. The fact that I cant set the Zero properly tells me there is some underlying problem with my configs of some thing the way calulations are being done different with openloop steppers.

Some further info. Always getting following error on Z axis (Joint 2). I have upgrade the PC now and have done all the tuning with the Os and interrupts.

I have been a week now, working every day to try and get this going after upgrading from from I think was 2.4, which seemed to work flawlessly for a good number of years.

I have also tried going back to 2.8.0, but still get the errors and the Zero button not working correctly.

When running a short program with the Z going up and down to cros the top of clamps the program will never run through, it always stops with a joint following error.

The other error i am getting is if I set the Deaband to 0, which it was the steppers are always vibrating.

Wondering if there are other hal file setting that have chnage since the earlier version.

This is driving me insane.

Picture of screen hot in next message showing that the position cmd and the fb are the same.

All help would be greatly appreciated.

I have just upgraded to 2.9.10 and still get the same error. Has anyone had any joy with this ?

can you post your config files?

Config Files attached.. I am using Technic and the high level feedback line to determine that the steppers are homed when they are enabled. The steppers will go to a hard stop then come back 1 rev for the home position, when this is done they signal this through the HLFB output. Other than that I think the configs are normal and haven't chnaged since my original install a number of years ago.