I think I'm on the low side on the DC voltage already at 130V, the drives are rated at 160V 36A. I haven't actually checked the Amps on mine though, cant imagine it being higher than that though?

The braking circuit didn't actually get damaged in use, it started smoking the second I turned on the power when I had the wires mixed on the transformer... I will get a new module on the way, like you say it will probably cause me more issues leaving a potentially (definitely) damaged unit wired up.

I'll try reducing the feed rates as well and see if that helps, it does seem that they initially start to move the axis a rotation or so then goes into error state.

I also had a rather scary issue with one axis, when I hit the reset button the axis just went into rapid on its own! Managed to hit the E stop before it done any mechanical damage to the machine ( hadn't wired up the limit switches at this stage) So i may have some encoder issues as well on that motor.