Thanks for the replies....
Danny, 64 bit is not checked. I never use it until export but thanks for the tip.
Alex, Yeah, did the reset and rescan of the plugs a few times thinking maybe the first time it didnt 'take' but no joy yet. This is why I was wondering about the older versions of the original Pro Channel FX. I noticed they don't get scanned like a VST does ( though Sonar may include that as part of the rescan process, not sure about that)
wetdentist, I wondered about that as well and went back to check and found that this project was indeed started in X3. Maybe something in the install process didn't take right. Next step is to do a complete re-install of X3...ugg!!! Grinds the whole studio to a halt