Added picture of the frustrated passengers 
I have 4 medium stand with no problem, but after adding 2 small stand the passengers will not board the airplane. I have de-zoned and re-zoned the secur area, saved and loaded, checked I have enough airport staff. Plane is ready with baggage and everything, only waiting for boarding. The boarding stand says Boarding, but it seems like they dont want to, or can go out the door to the plane. Now they are breaking my gate seats as well 
I answer my own question. Its just me being stupid. I had a small zone for staff only I forgot to remove after expanding my terminal this blocked the entrance and the exit to this terminal wing. The guys are not coming OUT of the terminal (and the nyew passengers are not coming in. I thought it was the outgoing passengers going crazy, but it was my incoming passengers.
Tip to improvement. (or maybe there is a function). It should be possible to cycle zones. When secure and staff zones are both on, and you have a wooden floor, its very difficult to see where both zones are.
Picture show the double zone right before the secure exit.
Are your passengers boarding now? Also can your airport staff get to the boarding desk?
Yes. All good now 
. Just had to remove staff zone. I see a common problem with ramp people on new stands not going to work. Need to save and reload to fix this.
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