Ok people i will try and answer some of the questions and i do understand that trying to fault find with little information is difficult and somewhat annoying.
I am using a desktop computer, dell optiflex running windows Xp 32 bit
the breakout board is from EGC TB6560 3rd generation, it has the display mounted on the board, but you see some with it on a ribbon cable
i will check to see if it requires a separate 12-24vdc supply, but i am using a dedicated 5vdc 5amp PSU to power the breakout board.
I will try isolating the limits within Mach3 and see if i can get the e-stop reliable.
When i am in the diagnostics of Mach 3 and i have managed to get it to reset for half a minute i can operate my micro switches and see the nice yellow LEDs light up so i know the signal is there what i dont understand is where Mach 3 is getting these spurious signals from, i am going to re jig my control box tonight and move the BoB away from the power supplies and other cables, just in case i am picking up electronic noise that could be causing dodgy signals