Okay here goes ...
Units = Inches
Stepper motor - 200 step / rev
Driver - 1/2 step -
Lead Screw - 10 tpi
X,Y Steps set - 4000 - no gear just ball screw
Z Steps set - 7000 (turns a worm gear)
Before the reformat ... I took the Z Drive and interchanged it with the X Drive ... no settings changed .. X Drive doubled ... and the Z Drive did not. Now I changed the motor pins around X over to Z ... changed the steps from 7000 to 4000 and it still doubled the distance. Changed the drive wires back and rechanged the Z to 7000 and it doubled the distance. Conclusion resulted in a fresh install. Same problem ... tried the non-locked down version same thing. From there I reformated the drive thinking that it is a Windows problem ... nope the problem remains.
The drives are optically isolated and are programmable for Full Step, Half Step, Quarter Step or 1/16 Step
They are flashed for 1/2 step and have been verified to be this ... If I change to 1/4 step or full the issue remains the same which is that it doubles the distance.
Since I have formated the hard drive with Windows 2000 the Z axis now also must be set to 3500 steps in order for it correctly move the distance.
Ratio's are working.
The driver test comes out excellent from 25 to 100 ... I have tried 25 , 35, 45 with a restart of Mach with each change.