OK!! I finally found the problem it was with a change made in the \includes\modules\YOUR_TEMPLATE\create_account php from the Captcha installation
Original create_account php from Captcha v. 2.9 11.08.2008
PHP Code:
// initial welcome
$email_text .= EMAIL_WELCOME;
$html_msg['EMAIL_WELCOME'] = str_replace('\n','',EMAIL_WELCOME);
if (NEW_SIGNUP_DISCOUNT_COUPON != '' and NEW_SIGNUP_DISCOUNT_COUPON != '0') {
$coupon_id = NEW_SIGNUP_DISCOUNT_COUPON;
$coupon = $db->Execute("select * from " . TABLE_COUPONS . " where coupon_id = '" . $coupon_id . "'");
$coupon_desc = $db->Execute("select coupon_description from " . TABLE_COUPONS_DESCRIPTION . " where coupon_id = '" . $coupon_id . "' and language_id = '" . $_SESSION['languages_id'] . "'");
$db->Execute("insert into " . TABLE_COUPON_EMAIL_TRACK . " (coupon_id, customer_id_sent, sent_firstname, emailed_to, date_sent) values ('" . $coupon_id ."', '0', 'Admin', '" . $email_address . "', now() )");
$text_coupon_help = sprintf(TEXT_COUPON_HELP_DATE, zen_date_short($coupon->fields['coupon_start_date']),zen_date_short($coupon->fields['coupon_expire_date']));
// if on, add in Discount Coupon explanation
// $email_text .= EMAIL_COUPON_INCENTIVE_HEADER .
$email_text .= "\n" . EMAIL_COUPON_INCENTIVE_HEADER .
(!empty($coupon_desc->fields['coupon_description']) ? $coupon_desc->fields['coupon_description'] . "\n\n" : '') . $text_coupon_help . "\n\n" .
strip_tags(sprintf(EMAIL_COUPON_REDEEM, ' ' . $coupon->fields['coupon_code'])) . EMAIL_SEPARATOR;
$html_msg['COUPON_TEXT_VOUCHER_IS'] = EMAIL_COUPON_INCENTIVE_HEADER ;
$html_msg['COUPON_DESCRIPTION'] = (!empty($coupon_desc->fields['coupon_description']) ? '<strong>' . $coupon_desc->fields['coupon_description'] . '</strong>' : '');
$html_msg['COUPON_TEXT_TO_REDEEM'] = str_replace("\n", '', sprintf(EMAIL_COUPON_REDEEM, ''));
$html_msg['COUPON_CODE'] = $coupon->fields['coupon_code'] . $text_coupon_help;
} //endif coupon
Edited create_account php
PHP Code:
// initial welcome
$email_text .= EMAIL_WELCOME;
$html_msg['EMAIL_WELCOME'] = str_replace('\n','',EMAIL_WELCOME);
if (NEW_SIGNUP_DISCOUNT_COUPON != '' and NEW_SIGNUP_DISCOUNT_COUPON != '0') {
$coupon_id = NEW_SIGNUP_DISCOUNT_COUPON;
$coupon = $db->Execute("select * from " . TABLE_COUPONS . " where coupon_id = '" . $coupon_id . "'");
$coupon_desc = $db->Execute("select coupon_description from " . TABLE_COUPONS_DESCRIPTION . " where coupon_id = '" . $coupon_id . "' and language_id = '" . $_SESSION['languages_id'] . "'");
$db->Execute("insert into " . TABLE_COUPON_EMAIL_TRACK . " (coupon_id, customer_id_sent, sent_firstname, emailed_to, date_sent) values ('" . $coupon_id ."', '0', 'Admin', '" . $email_address . "', now() )");
// if on, add in Discount Coupon explanation
// $email_text .= EMAIL_COUPON_INCENTIVE_HEADER .
$email_text .= "\n" . EMAIL_COUPON_INCENTIVE_HEADER .
(!empty($coupon_desc->fields['coupon_description']) ? $coupon_desc->fields['coupon_description'] . "\n\n" : '') .
strip_tags(sprintf(EMAIL_COUPON_REDEEM, ' ' . $coupon->fields['coupon_code'])) . EMAIL_SEPARATOR;
$html_msg['COUPON_TEXT_VOUCHER_IS'] = EMAIL_COUPON_INCENTIVE_HEADER ;
$html_msg['COUPON_DESCRIPTION'] = (!empty($coupon_desc->fields['coupon_description']) ? '<strong>' . $coupon_desc->fields['coupon_description'] . '</strong>' : '');
$html_msg['COUPON_TEXT_TO_REDEEM'] = str_replace("\n", '', sprintf(EMAIL_COUPON_REDEEM, ''));
$html_msg['COUPON_CODE'] = $coupon->fields['coupon_code'];
} //endif coupon
These are the lines I removed as this is what was making it show up in email.
Starting from top down:
PHP Code:
. $text_coupon_help . "\n\n" .
$text_coupon_help = sprintf(TEXT_COUPON_HELP_DATE, zen_date_short($coupon->fields['coupon_start_date']),zen_date_short($coupon->fields['coupon_expire_date']));
. $text_coupon_help;
I hope everyone can understand what I did
and that it may help someone else if they have the problem after installing Captcha which by the way is a fantastic add-on 
Kind Regards
Paul