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You mention 5 wires. Are these the 5 wires that come from the controller?
From pictures of the KDM, it seems that these are the only 5 wires.

That means that the KDM itself is a "computer", that...

You could try opening MultiCam Motion Mechanic with the connected computer.
While the board is booting, it should output some startup info, and possible error messages there.

After connecting the...

If you're talking about the rapid moves executed trough the plotter file, the manual says "the Feedrate Override has no effect when the machine is executing a rapid move above the material". The...

Are you talking about the plunge-rate of the spindle into the stock (Z-axis movement)?
The X-Y movements should be the exact same as a true run. From what I see, dry run mode doesn't run the Z-axis....

Short answer to the above, in case anyone else wonders :)
There is no need to replace ALL drivers if you replace just one with another driver.
You can replace it with absolutely any 2-phase stepper...

What happens in a dry-run? Does the last pass actually go where it is supposed to? (Use a lump of Styrofoam or something along the path).
If the dry-run actually passes where it is supposed to, you...