I replaced my opto-isolated breakout board with a non opto-isolated one and all the problems went away. I am now able to rapid all the axis at the same time at 200 ipm smooth as glass, no lost steps. I could probably go to 300 ipm, but the mill is still up on 4x4 blocks waiting for a move and it rocks more than I am comfortable with.
Now that I have the drive system up and running, I am moving forward with some of the other controls. I hooked up the powered draw bar and after replacing some air lines, it works well. I am at a loss though with how the spindle brake was connected. It should interface with the draw bar or the draw bar will spin the spindle. I can't figure out how they did that. The brake has a solenoid that operates the brake. The brake needs to engage on both the tighten and loosen cycles of the draw bar. The only way I can see to make it work is through 2 relays, and it was not hooked up like that when I got the machine.
I also need to run the fault and reset signals to the control panel. Otherwise I have to open up the pendant to reset the drive. I tend to fault the drive by not having the drive power on before attempting an axis move.
Anyway, things are looking up. I had spent almost 2 weeks trying to track down the noise problem.
Vince