looks like I fixed this by adding my own equipment profile for each Batch size....then changing it on all of my recipes. even so, the generic 10 gallon pot and cooler I was using for everything said boil off was 1gallon. the equipment shouldn't affect the boil off by double. it was adding 2.5 gallons to the pre-boil on 5,5 gallon batches.
oh well got it straight