OK, here are some suggestions I have cooked up for the army composition and limitation of the armies of the Hellenes.
Epeiros - 1 type of army (Reformed Pyrrhic)
Infantry: A mixture of phalanx with flexible infantry and phalanx as a solid line. This means basically the main line should be phalanx-infantry-phalanx-infantry etc. Illyrians can and should be used by any extent (Illyrioi Thorakitai/Thureophoroi, Illyrioi Parktioi) as flankers, as well as traditional Thureophoroi/Thorakitai, Peltastai and Hoplitai (Haploi and normal). As for mercenaries, use of Pezoi Brettioi and Samnitai is acceptable, as historically they helped Pyrrhos in his campaigns.
Cavalry: Heavy cavalry about 4 units max. Campanians excluded. 1 unit of Elephantes Indikoi maximum.
Ranged: 4 units of missile troops (including Kretikoi/Rhodioi Sphendonetai and excluding Akontistai) maximum.
Makedonia - 2 types of armies (Late Alexandrian, Reformed)
Late Alexandrian Army
Infantry: A solid line of phalanx troops (about 8) of mixed quality (Deuteroi, Pezhetairoi, Misthophoroi Pezhetairoi, Argyraspides). Thureophoroi, Agrianikoi Pelekophoroi, Peltastai (including Thraikioi), Hoplitai (Haploi and normal) for flankers.
Cavalry: 4 units max. More accurate, it should be even less, about 2-3. This includes the Strategos.
Ranged: 4 units of missile troops (including Kretikoi/Rhodioi Sphendonetai and excluding Akontistai) maximum.
Reformed Army
Same as previous, but instead of Pezhetairoi you have the Hysteroi guys. And quite many of them as well (about 4 out of 8). Also, use more mercenaries than normally, with Thraikioi and Illyrioi being the norm.
Koinon Hellenon - 2 types of armies (Iphikratean, Reformed 'Successor')
Iphikratean
Infantry: Iphikratides or hoplites as a 4-6 unit solid main line, as well as 2 elite hoplites (including Strategos). Normal hoplites can be used as flankers as well as Thorakitai/Thureophoroi/Peltastai (and Thraikioi).
Cavalry: About 2-3 units (Hippeis, Hippakontistai). No Thessalikoi.
Ranged: 4 Toxotai/Sphendonetai (including Kretikoi/Rhodioi Sphendonetai and excluding Akontistai).
Reformed 'Successor' Army
Koinon Phalangitai and Misthophoroi Pezhetairoi (2 maximum) as a main line, as well as the same flankers as the Iphikratean one. Hoplites and Iphs can be included. 2 elites as well (Strategos included). Xystophoroi can be used as well, but 1 unit maximum. 2-3 units of cavalry all in all.
I'll come back for the Diadochoi, but first I'll list here the possible matchups:
Epeiros vs Romani --> Reformed Pyrrhic - Camillan
Makedonia vs Romani --> Late Alexandrian - Polybian or Reformed - Polybian
Koinon Hellenon vs Romani --> Traditional vs Polybian or Reformed Iphikratean
Maion
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