As suspected the problem was the RJ45 sockets. Although the old ITT-Cannon cat5 modules were small and neat, they were not properly crimping the motor wires, even after some gentle persuasion. I have replaced both with TE cat6 modules and the whole unit now works perfectly. I quite like the idea of data modules for the motor and one wire connections, as they are light and I can easilly swap around and choose patch lead length to suit. Though it would make for a neater project if I could find some modules that soldered directly to 0.1" pitch veroboard. Otherwise DB9 plugs and sockets are the usual way to go, but heavier, bulkier and not so neat to my mind.