“Free Run” did the trick !! (it is always the simple stuff) I changed the CONTROL -> GENLOCK -> to “freerun” and the material lay-ed off flawlessly. this worked with the Kona routed to the deck, and the deck routed to the Kona (a loop). to be sure we switched back to the “ref-in” and the problem re-appeared.
CONTROL -> GENLOCK -> FREERUN produced a clean 720p output. thank you everyone for the help
-Tom
Actually, I would change the Kona Ref to Free Run. Also make sure that no sync is connected to the D5. The issue may be that your sync is just a little off. The Kona cards are hyper-sensitive to imperfect sync.
Jeff Bernstein