I definitely don't get 0 volts it's A constant 6.5 - 7volts   no matter what change is made enabled or disabled.

If you are shure you did the tests with port 1 not accedently wit port 2 then it looks like something is burned, but hard to say from a distance.
Alex

I use Port 2 for another breakout board and additional outputs for flood coolant and mist solonoid. And everything else works fine on g540, smooth stepper and c10 BB with no issues. But I do know that if the g540 vfd I/O gets smoked it it's isolated and won't effect anything else. I will ship it to gecko to test and fix the problem. Thank you very much for your help . Hopefully when It returns I can get this going.