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The desk is still faulty, the singer said he had checked it but he hadn't really!!
I've now got my hands on it and the problem is still there. I had a KV2 EX12 speaker hooked up to the desk testing it with a mic in my house. With the gain at 10 o'clock, channel fader full up and master full up, it was way down on volume, I mean you could shout over it and be heard no problem.
So it's now gone in to a local repair shop to see what they can do.
@Danny1969 I've advised them of what you said the problem probably is, so they know what they are looking for when they open it up.
Thanks for all the help guys.
"Take these three items, some WD-40, a vise grip, and a roll of duct tape. Any man worth his salt can fix almost any problem with this stuff alone." - Walt Kowalski
"Only two things are infinite - the universe, and human stupidity. And I'm not sure about the universe." - Albert Einstein
He took the pedalboard out of the equation and plugged straight into the amp using the JVM footswitch and it worked fine from then on.
I've also got my eye on the new soundcraft signature 16 mixers. 3 aux sends which at a push we could manage with. Looks like it could do the job. The idea of buying new appeals as you get a warranty with it.
@Danny1969
Update on the desk. Initially the place where we took the desk for repair couldn't find anything wrong with it, although digital mixing desks were not really something they were familiar with. When I spoke to them earlier in the week they told me that they had the desk on 'test' for a couple of days and couldn't find anything wrong with it.
I sent them a link to this thread so they could see all the things that had been suggested, especially to what you had said @Danny1969.
When I rang on Thursday they said they had opened the desk up and noticed something had been spilled on it that had got inside, they said it was on the main board and some of the faders, they said it looked like it had got in through the vents on the side, I don't really know how this happened as it's been racked up for most of it's life.
Anyway they said they cleaned it all up inside and said the desk output from the stereo outs was now registering over double what it was before. So it would appear that's what the problem was.