wow, thanks guys for all the info. I'm at work at the moment but late last night I had a quick look at the settings and my velocity looks way too high. I have found someone elses motor settings for the 6040 machine and Mine is at least 25‰ greater! no wonder why I'm having issues. I'm going to get in tonight change the settings and report back. Thanks to you all for your input. will be good to see this fixed lol. got my fingers crossed for tonight. I will screenshot the settings for anyone else with a similar machine should this quandry happen for others.

I'm sure I won't be the first ;-) cheers guys