Tom,
I solved my encoder skipping issue. I needed to use the same 5VDC power supply to drive Kflop and my encoders. Failing to do so caused the dropped encoder counts. My X,Y,Z axes now count perfectly in Kmotion "AXIS" display screen. I am not using the ZR+ ZR- wires for the X,Y,Z axes for anything yet. They are connected to the board, but not software programmed.

X and Y axes are connected to Gettys N360 Half wave SCR drives (+-10VDC) controlling Gould M113-A10K-900A 12.5 amp DC brushed motors.

Set I = D = 0
Set P gain = 0.1
Downloaded the Configuration and Parameters using the "Enable" button on Step Response Screen
Verify System Servos (Servo is holding now that I changed input from 1 to -1 ...holds position and resists turning)
Set Size of move to 200 counts and time to 1 second on the Step Response Screen
Pressed "Move". Output is available at Files folder "Tree 320 3-Axis Mill\ step response screen.doc"


NOW I HAVE QUESTIONS AGAIN:
1) point me to directions that show me what a good step response screen should look like. Based on the diagrams you just looked at in step response screen.doc ...what changes I should make from where I currently am.

2) Over travel switches and home switches ...is the kflop diagram (in same folder) the correct way (and optimal way) to wire these? Do the JP4 pins 5-7 & 10-12 have 3vDC output and I just need to go to ground (pin 8 or 9), or are pins 5-7 & 10-12 grounds and I need to supply 3VDC from pin 3? If these are connected to simple limit switches, do I need a diode or resister ...and if so please show a diagram showing how to wire it. Or should I be using Kanalog JP-15 opto inputs??

3) To start my system I need to close a relay (15VDC) to ground. I assume "JP8 terminal 0" on Kanalog is the correct location for this, but I have no idea how to wire it so the switched output is used as one of the conditions to enable main system power for motors and drives. I understand "reverse diode connected in parallel with the load" ...but a diagram or photo would do wonders for those of us who don't have any idea what a reversse diode is (a diode - yes. reverse diode - no) nor how to install it in parallel since I don't know how to connect the watchdog wires either.

4) this is almost identical to 3 ....Need to close a relay to supply 24VDC from a relay to start the spindle. "JP8 terminal 1" and somehow this should have a reverse diode too? How since this is 24vdc and the other circuit is 15VDC?

That should get the mill up and running with limits switches and safety start circuits.

Thanks,
Gregg

PS sorry for the novel.

I should clarify for those who have encoder skipping questions: "I needed to use the same 5VDC power supply to drive Kflop and my encoders".

That statement may be a bit misleading. While I initially connected the encoders and Kflop using the same power supply (spare computer power supply from a old computer that I owned). This made it easy o test the boad and learn a little about the software without having a live mill connected to it. Unfortunately once I connected it to the mill ....it wasn't the same 5VDC that the rest of the mill uses. It also used a different 110VAC wall plug. One of these items caused a floating ground issue.

While I'm sure I could have resolved that floating ground issue ...it was easier to use the existing 5VDC on the milling machine that was previously used for the mill's old computer.