Had another go at it....with the same results.
Completely uninstalled MACH..the entire directory on the C-drive, which deleted the XML file as well; the Pulse Engine was deleted in the Device Manager; cleaned up Windows Registry with CCleaner, even used MS Disk Cleaner and MS Defrag for good measure.
Reinstalled the latest version and reconfigured this with parameters needed for the Shop Droid.
On the off chance there was a problem with stepper motor, switched the A-motor with the X-motor. A-motor works correctly when wired to X-axis output on controller board. X-motor does not work correctly when wired to A-axis output on controller board.
Sending both controller board back to Rockcliff to have them checked.
That will give me time to build a computer for EMC2/LINUX and tinker with it. Might as well do something while loosing all this production time. Might even clean up the studio!!
Also talked with the folks at FlashCut CNC. I am intrigued. Have to see how senior management reacts before I get too enamored.