The problem is this the same.
The problem is the same... as this?
When I power it up for the first time I flip on the main breaker. This power the 126 card, 24vdc supply and the cooling system. The Estop is set because I have not set my emergency buttons.
Once all are in the open setting the 134, Gicko's and the relay wired to the Fault get power. The button (to repay) in the box by my spindle is the only thing hooked up to Estop on 126. Now the Estop light goes out and all is good to go.
Now if at sometime later if I push one of the E buttons the system stops and goes into Estop. This is right. But is I reset the buttons the 126 Estop will not reset until I either turn off power to 126 or close Mach3.
There is still too much missing information (at least to me) in your diagram. You commented somewhere previously that two of the relays were actually wired in series, but I don't see that in the drawing. And do you really have 7 EStop switches in your system (3 shown to the left of the main 230VAC, 3 shown to the right of the main 230VAC and one shown on gantry)?
Do you have anything connected to the ERR+ and ERR- terminals on the PMDX-126 (located just above the Fault terminal)?
If you are still having the issue shown above, lets try something different. Do you have DC voltmeter? If so, the next time the PMDX-126 shows EStop (red LED is on and won't turn off when you think it should), measure the voltage between the EStop terminal on the PMDX-126 and the adjacent GND terminal. Also measure the voltage between the PMDX-126's Fault input and the adjacent GND terminal.
In order for the PMDX-126 to come out of EStop, the EStop terminal must be close to 0V (say less than 0.5V, roughly), *AND* the Fault terminal must *NOT* be close to GND (say, above 3V, roughly - but I need to make some measurements when I get in the office later today). Also, the voltage from the ERR+ to ERR- terminal must be close to 0V (not referenced to GND, rather ERR+ referenced to ERR-).
Let us know what voltages you measured in these 3 places. If they are not as described above then we need to figure out what is either pulling the Fault input to GND or NOT pulling the EStop input to GND.
Bob