Aaarrrggghhhh!
I'm pleased to say the +/-50V rails are now working and my FAIL 7 error is gone, but I'm not particularly pleased with how long it took and how stupid I am!
So I shorted the current sense resistor and yet the problem still persisted, so that was good, it meant the issue was squarely with the current limit circuitry and not anything to do with turn-on spikes etc.
So I replaced the two tantalums, no change. Replaced the three transistors (one at a time), no change. I replaced the 1N4148's, no change, I removed and re-tested the two zeners, they seemed fine. I retested all the resistors, they were fine. I swapped the ceramic cap.
So I'd changed or tested every single component and it still wasn't bloody working!
Because I'd removed two of the heatsink assemblies I had a bit more room, I could start putting test clips on various components, and I eventually found that the 5.2v zener anode, which should have been at -75V (ish) was at -35V ... how can that be? It's directly connected to the darlington and I can probe that on the connector and it's -75V??
Anyway, it turns out that it's not directly connected to the darlington, because a small bit of the copper track had come away, so I've just spent hours (and a fair few quid on components) to solve a bloody track defect.
Sigh. Lesson learnt.
Before and after pictures attached for embarrassment. I've also included a picture of my multimeter with 1v output set, this was only a few minutes after power-up (ignore the historical stats) ;-)
Now to move on to the 1A current range problem ... although I'm going to save that for tomorrow and crack open a beer instead.
Thanks for your help Johnny10.