I'm trying to help an internet friend, so I have no access to the machine. He installed PP on a new PC and specified 1100-2 on the install.
I was surprised to find that there is no tormach_1100-2.ini file generated; rather there is an 1100_3 INI file. So we have no way to know if the control boards for V2 vs. V3 are significantly different in terms of pins or the proper 5i25 bit file. Currently he reports that he can jog the axes, but trying to reference them generates buzzing at the machine and no axis movement.
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My 1100-2 (mid-2009) has the original control board, though I've done the upgrades to steppers & drivers (sometime in 2011/early 12). No problems at all with any PP release, I've been using it since the late beta.
The motion upgrade preceeded the PP install. I don't recall needing to identify my machine model when I switched. Doesn't mean I didn't, but I am sure I haven't with recent updates. As I understand the "updates", they are really complete reinstalls of the entire system.
As usual, I'd call Tormach for questions like these.
There is essentially no difference between the series 2 and series 3 control boards other than some additional functionality programmed into the controller chip. It sounds like you're trying to run a series 2 (with the 2 phase stepper motors) with a series 3 ini configuration. The only difference between the two configurations are the maximum feed rates and accelerations. The series 3 accelerations are twice the values set for the series 2 and it sounds to me like the series 2 steppers can't handle this. Try renaming the config_file.txt and restart PathPilot. You'll get a message saying that the config file can't be found and then you'll be able to re-select the required configuration. Be sure to select "Find your machine here" which will bring you to a list of all PCNC mill versions.
Good luck
Step
Problem has been resolved; user had failed to read the manual.