We replaced our stepper driver on the push feeder west side last year and have been unable to get it working properly since. It seems to function smoothly until we try to zero the machine with the feeder too far from the sensor / flag. It moves toward the flag, but then stops and errors (almost like there's a time limit). If it is less than about 2/3 of the travel from the flag, it will home without throwing the error, but that furthest 1/2-1/3 of the travel cause the error and then entire software needs to be reset, I can't even hit the home button again to get it to finish.

I have set the motor current to 1.797A at its maximum point by running through the steps in fine stepsize / speed, then adjusted the current potentiometer. I have also ran the calibration, and with a target of 200mm, am getting 199.9996 with a 68.818 pulse calibration parameter (which seems to be about 2x what it was when I started troubleshooting. This is concerning, but I cannot find a valid range in the manual, so I assume for now the near match on distance is verification enough (is it?)

The dip switch settings on the drive for that arm stepper are:
1,2,3: Off, Off, On (Fast Decay) (no mention in the manual that I could find?)
4: Off (Full Stream Mode) (no mention in the manual that I could find?)
5, 6, 7: On Off On (1/16 step size) (Pretty sure I saw this in the manual somewhere)

Where am I going wrong here? I don't want to re-set / program all the push locations if i don't have to, but what I definitely don't want to do is reprogram them, then have to redo it because some other combination of hardware / software settings needs to be changed in order to get the homing to work properly.