New day new problem

Ok, The error you are seeing is because you have some inconsistencies in your ini file.

This is what I have in my ini file with home switch at top (in mm)
So converting to inches with 4" of travel, it should look similar to

Thanks Tommy's cryptic message made my look intently at the INI file and where the problem was in the upper part the is another max and min, which I was not changing. The 2 locations need to read the same values. It now will not move the Z up at the start of an operation. I set all DROs to zero and I am using the wrench G-code from the examples with a material selected from the list (45XP).  Now I have a floating head switch but it takes about 3 push ups when the the Z is moving down to find the metal surface. After doing that it will move to 0.060 on the DRO and proceed with the G-code to the end without other problems. But at the end the Z DRO is showing -0.0969.  Could the debounce setting for the floating head switch be causing the problem with the switch action.   I looked in the Custom Hal and all the switches are set to 5, not sure if my (bumping up) pushing up on the switch is to fast.

Tom, can you share your ini file again? Just so we know what is going on?

Now I have a floating head switch but it takes about 3 push ups when the the Z is moving down to find the metal surface.
That normally means that the probe height is too low, probe height is measured from the bottom limit, not the material. How far below the top of the material is your bottom limit?

Maybe about an inch, so I think your saying to raise the torch in the holder so there is less of a distance?

No, just set the probe height to be 3" to start with and then change it down to 2". It must be above the distance below the slats + material thickness. YOu should see it rapid down to probe height and then advance at probe speed

Ok things are getting much better, attached is the INI, Hal, and custom files you requested.  There are 2 sets last chance saloon is the last and seems to have the axis acceleration and velocity working like I think they should.  the other one is mostly the same except for the speed setting.
The problem I had talked about with the floating head switch was my simulating the touching of metal surface by lifting up the torch quickly.  I put some styrofoam on the slates and started a G-code and all worked as expected.  The fact of the Z DRO showing -.0969" after the g-code ran if I set it to zero the next time I ran it it showed 0.00' when it ended the G-code. 
The ohmic sensor does not seem to work, but maybe that will be another day.
It has been a long slog and you guys stayed with me and I would like to thank all of you.

 
 

You don't need to worry about the Z DRO value after a cut. Most folk jog their Z all the way down, set that to zero them never worry about about it again.

understand that is what I did with the other table, thanks for the reply.
Getting down the road with this after much help.