Hi Charles,
One possible source of confusion might be the how the Coordinate Motion System is defined. I believe you had:
DefineCoordSystem(0,1,2,-1);
The Spindle should not be included in the Coordinate System if operated as a Spindle. And this defines X=axis 0, Y=axis 1, Z=axis 2. So when Jogging the Z axis the Spindle is being commanded. And when any Jogging is stopped all axes are stopped. I think it should be:
DefineCoordSystem(0,-1,1,-1);
To define X=axis 0, Z=axis 1 and no others.
I don't think that explains everything though.
This of course should never happen, No matter how jerky or erratic the Spindle motion is the encoder should track the position without loosing count. The only thing that should change it is a reset of the Encoder Position or a re-boot. So you might investigate what causes this. If it ever looses count something is wrong.Move2=0 took spindle to the second mark from yesterday. After jogging axis, would sometimes go to mark and sometimes not.
This is correct on the Kanalog end. But the question is whether they are connected to the correct signals from the encoder.The black wires in the encoder cable are shielded/twisted pairs as grouped above. The black pair connected to 0V are combined and the red/white pair are combined. The others are not combined. The other black wires are the positive compliment to the paired colored wire and are connected to A2+, B2+
You could disable the Spindle Amp or unplug it so it has no power and should then sit still. You can then check A+ A- B+ B- are all at valid levels and complementary. Then rotate some random amount until all 4 possible states are checked.Tried to test voltage on the encoder wires to ground, but even at .5 RPM, my voltmeter may not be fast enough to keep up. Showed about .8 - 2.8 volts.
The Plot 128 shows some small DAC shift and interaction. The axis also seems to be on the verge of instability. I thought I saw earlier plots with D=15 and much more stable. But the instability doesn't explain the shift. Before the Jog the DAC is about -14 to hold position. After the Jog the DAC is about -24 to hold position. Its not clear when you stopped the Jog and if the offset persisted or only exists while Jogging. A 10 DAC counts shift is 10 / 2047 x 10V = 49mV. I suppose it could be a defective Kanalog. You might try using DAC 4 for the spindle as a test.
I think you have those deadband Programs writing to the DACs? Do you? Maybe those have a bug. Please post them. You might eliminate those to see if that's the cause of the interaction.
Sorry for no simple answers.