Kossel Calibration Problem

I picked a Mini Kossel as my first printer, but the openbeam that arrived was for a Legacy Kossel, so I built a Mini with the 360 mm base beams and 600mm tall. The rods are 312mm hole center to hole center and the base is 250mm diameter. It uses wheels instead of rods (quiet and smooth). My probe is offset to the right instead of the back and I intend to move to a servo, but right now it is the long allen wrench with a very small microswitch on the end, so the probe offset is x 15, y 15 and z -9.

When I issue a G28 it homes and with a G29 it calibrates with 29 samples (it seems a bit skewed to the front, but it stays on the glass). If I home it, the z says 185 which is what I entered for the MANUAL_Z_HOME_POSITION. When I issue a G1 X0 Y0 Z0, the hot end stops 5 mm above the glass. I have changed both the MANUAL_Z_HOME_POSITION which was 180 (and that is what I measure, it was 175 before that) and the probe offset which was -5 (I have tried 0, 5, -5 and now -9). The position of the head after giving it the G1 X0 Y0 Z0 is always 5 mm above the glass. I have looked at the code and don't see anything obvious. The startup and calibration output follows:

07:17:14.841 : start
07:17:14.841 : echo: External Reset
07:17:14.841 : Marlin1.0.0
07:17:14.841 : echo: Last Updated: Feb 24 2014 07:15:39 | Author: (lreinhart, Mini Kossel)
07:17:14.841 : Compiled: Feb 24 2014
07:17:14.841 : echo: Free Memory: 2965 PlannerBufferBytes: 1232
07:17:14.841 : echo:Hardcoded Default Settings Loaded
07:17:14.841 : echoteps per unit:
07:17:14.841 : echo: M92 X100.00 Y100.00 Z100.00 E100.00
07:17:14.841 : echo:Maximum feedrates (mm/s):
07:17:14.841 : echo: M203 X200.00 Y200.00 Z200.00 E200.00
07:17:14.841 : echo:Maximum Acceleration (mm/s2):
07:17:14.841 : echo: M201 X9000 Y9000 Z9000 E9000
07:17:14.841 : echo:Acceleration: S=acceleratm/s), B=minimu acceleration
07:17:14.841 : echo:M204 S3000.00 T3000.00
07:17:14.841 : echo:Advanced variables: S=Min feedrate (mm/s), T=Min travel feedrate (mm/s), B=minimum segment time (ms), X=maximum XY jerk (mm/s), Z=maximum Z jerk (mm/s), E=maximum E jerk (mm/s)
07:17:14.841 : echo: M205 S0.00 T0.00 20000 X20.00 Z20.00 E20.00
07:17:14.841 : echo:Home offset (mm):
07:17:14.841 : echo: M206 X0.00 Y0.00 Z0.00
07:17:14.841 : echo:Endstop adjustement (mm):
07:17:14.841 : echo: M666 X0.00 Y0.00 Z0.00
07:17:14.841 : echoID settings:
07:17:14.841 : echo: M301 P7.00 I0.10 D12.00
07:17:18.569 : echoD init fail
07:17:18.632 : echo:Unknown command: ""
07:17:18.647 : FIRMWARE_NAME:Marlin V1; Sprinter/grbl mashup for gen6 FIRMWARE_URL:[github.com] PROTOCOL_VERSION:1.0 MACHINE_TYPE:Len's Kossel EXTRUDER_COUNT:1 UUID:00000000-0000-0000-0000-000000000000
07:17:53.482 : Bed x: 0.00 y: -120.00 z: 11.90
07:17:54.746 : Bed x: -80.00 y: -80.00 z: 12.70
07:17:55.791 : Bed x: -40.00 y: -80.00 z: 11.62
07:17:56.696 : Bed x: 0.00 y: -80.00 z: 10.80
07:17:57.538 : Bed x: 40.00 y: -80.00 z: 10.43
07:17:58.412 : Bed x: 80.00 y: -80.00 z: 10.62
07:17:59.457 : Bed x: 80.00 y: -40.00 z: 9.89
07:18:00.331 : Bed x: 40.00 y: -40.00 z: 9.70
07:18:01.095 : Bed x: 0.00 y: -40.00 z: 10.08
07:18:01.859 : Bed x: -40.00 y: -40.00 z: 10.82
07:18:02.686 : Bed x: -80.00 y: -40.00 z: 11.94
07:18:03.778 : Bed x: -120.00 y: 0.00 z: 13.08
07:18:05.042 : Bed x: -80.00 y: 0.00 z: 11.61
07:18:06.056 : Bed x: -40.00 y: 0.00 z: 10.50
07:18:06.992 : Bed x: 0.00 y: 0.00 z: 9.74
07:18:07.881 : Bed x: 40.00 y: 0.00 z: 9.45
07:18:08.708 : Bed x: 80.00 y: 0.00 z: 9.61
07:18:09.613 : Bed x: 120.00 y: 0.00 z: 10.38
07:18:10.642 : Bed x: 80.00 y: 40.00 z: 9.83
07:18:11.563 : Bed x: 40.00 y: 40.00 z: 9.58
07:18:12.358 : Bed x: 0.00 y: 40.00 z: 9.79
07:18:13.154 : Bed x: -40.00 y: 40.00 z: 10.45
07:18:14.027 : Bed x: -80.00 y: 40.00 z: 11.45
07:18:14.917 : Bed x: -80.00 y: 80.00 z: 11.77
07:18:16.009 : Bed x: -40.00 y: 80.00 z: 10.90
07:18:16.945 : Bed x: 0.00 y: 80.00 z: 10.29
07:18:17.803 : Bed x: 40.00 y: 80.00 z: 10.11
07:18:18.676 : Bed x: 80.00 y: 80.00 z: 10.45
07:18:19.831 : Bed x: 0.00 y: 120.00 z: 11.13
07:18:19.846 : 13.900 13.160 12.420 11.900 11.160 10.780 10.580
07:18:19.846 : 13.380 12.700 11.620 10.800 10.430 10.620 10.330
07:18:19.846 : 13.060 11.940 10.820 10.080 9.700 9.890 10.080
07:18:19.862 : 13.080 11.610 10.500 9.740 9.450 9.610 10.380
07:18:19.862 : 12.450 11.450 10.450 9.790 9.580 9.830 10.080
07:18:19.862 : 12.400 11.770 10.900 10.290 10.110 10.450 10.210
07:18:19.862 : 12.670 12.010 11.350 11.130 10.640 10.430 10.340

I was really excited to see it home and do the calibration. Does anyone have an idea why it is stopping 5 mm above the glass? Any suggestions as to how to proceed?

Edited 2 time(s). Last edit at 02/24/2014 08:53AM by Len.