Channel Value Issue Between Photoshop 6 and CS3

We use a specialized process that includes Channel operations to make separations for printing. When we use the same process that we have always used in any NEW photoshop, the value are completely different. This is best illustrated by opening a PS5 file and looking at the channels. we open the file in CS3 and look at the darkest value. we then they to fill an area of that same color in that channel and it is lighter, BUT CS3 says that it is the SAME value. we are blown away and cannot figure out what we are doing. We have tried color settings, everything. My boss even contacted Adobe tech support, had them recreate the problem and they say that they had no idea why it works like it does. I know that this is a long rambling post but if anyone has the slightest inkling of how to help i will accept any and all offers!
Thanks.

I am fairly certain that the way that Dot Gain was calculated or applied was also changed at some stage in the evolution of Photoshop?
It seems that it did! I have just found this (it dates from a piece I posted in 1998!):
Incidently, the Dot Gain algorithm has been changed in Photoshop 5.0.
Dan Margulis has discovered the formula for translating these values and I am repeating it here in case people missed that posting.
Starting with your known Photoshop 4 Dot Gain,
Subtract that dot gain from 40
Multiply the result by .33
Add 3 to that number
Subtract that number of points from your dot gain to get your PS 5 equivalent.
That would make a PS 4 Dot Gain value of 29% work out as:
40 - 29 = 11.
11 x 0.33 = 3.63
3.63 + 3 = 6.63
29 - 6.63 = 22.37 Dot Gain in PS 5
Hope that helps.

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