Erratic behaviour and a big sketch are both hints that you may have out-of-memory problems. I haven't looked at your source but I suggest that if you're using the String class you stop doing that. Also add up the number of bytes of global data and the number of bytes of literal values (especially string constants) throughout your code and subtract from the amount of RAM on your Arduino (e.g. 2KB for a UNO) and see whether you're anywhere near close to running out. If this doesn't make it obvious, look on the playground for a code fragment to measure the free memory and make your sketch log that at startup.
Thanks, I don't think I'm using the string class anywhere but finder shows my sketch is 15kb. Is there a better way to handle large sketches? I'm sure others have larger sketches than mine. Is this where I stop using uno and go to the mega?
Thanks for your help!
PaulS: Thanks for the reply! I know that I am a very inefficient coder and appreciate every tip offered to me. I've never used the F() macro so i'll look into that now. As far as the "tcoh" that simply refers to a physical location in our plant. We have an overhead door and a man door entering to a room called " time clock" where employees enter the facility and actually punch a clock. And as for the increment, are you saying all i have to do is simply have d1ocount++; ? If so I understand how silly, and redundant, my code looks!
Thanks again for the help guys!