Hi Tom,
Have you ever had any issues with the connections between the screw terminals and kanalog board? Or maybe the connection between Kflop and Kanalog?
My spindle override knob started acting funny today. Bouncing around all over the place. Analog voltage in kmotion showing low, but I verified higher voltage at the screw terminal, and wire was tight. Lightly tapping the chassis where Kanalog/Kflop is mounted seemed to make the problem come and go. I just removed the screw terminal block and reseated it and seems ok so far. Is it likely that the problem is between the terminal block and the board? Could it be between Kanalog and Kflop or is it less likely to be that connection?
I wonder if this was the same trouble I was having with my Y axis encoder input a while ago? Would it be a bad idea to remove the terminal blocks and solder wires directly to the pins?