Hi Jayybone,
I don't doubt you when you say that your system worked well in the past but there is something wrong here.
The HobbyCNC driver board expressly states that it is not suitable for use with Bipolar stepper motors yet you say that you are using it with Bipolar stepper motors. If this is truly the case then, unless you have electrically connected your motor windings into the Unipolar configuration, it is more than likely that your driver board has been damaged and this is the issue which may be causing your current problems.
Tweakie.