Like a dog with a bone I have solved it!
This morning I did a high current test with one of those Johnson motors that the ill informed on here don't like.. Using a 7.4v LiPo with an 8" aircraft prop on, I ran it for about six minutes and it refused to trip, most annoying.
I then spoke to the importers and asked if they had encountered any issues with these speed controls. Turns out the only return they had had since November had been sent back by me.. cursed I am.
Next test after it had been bothering me for the better part of the day, involved a Torpedo 800 with a 10x6in wooden aircraft prop on it, using a 12v gel battery. It tripped after thirty seconds. So, fine on the lower voltage, but not happy on the higher one?
Nope, after a bit of brainstorming and checking the programming parameters, and trying options to see what happens. It turns out that line 2 of the programming which relates to the choice between LiPo battery and NiMh battery has been transposed, so what I thought was a NiMh setting with no low voltage protection, was in fact set to LiPo, and as the gel batteries voltage rapidly sagged to eleven and a few bits volts the LiPo (NiMh!!) setting tripped out the speed control to protect the LiPo (gel battery!!) from over discharging.
I have all but confirmed this by testing a few variable options, and getting the same results. So once I have tested another four that were returned by a customer, I shall re-install, again, the QR880 in the tug and take it out for a test sail.
So, only goes to prove, sometimes when problem solving, we all have blinkers on!
Post script, I have a distant memory of a batch of Quicrun 860s from about three years ago, doing exactly the same thing..