Managed to locate the trace command in the US Robotics 9003 router ('sndcp
ppptrace on' from a telnet session).
From a working session....
ADSL Link ESTABLISHED !
ppp

atalink : ppp0: Created in Dead state
ppp: FSM: Using "ppp0" as a transport
ppp: FSM: ppp0: State change Initial --> Closed
ppp: FSM: ppp0: State change Closed --> Req-Sent
ppp: FSM: ppp0: RecvConfigReq(116) state = Req-Sent
ppp: LCP : ppp0 : MRU[4] 1500
ppp: LCP : ppp0 : AUTHPROTO[5] 0xc223 (CHAP 0x05)
ppp: MAGICNUM[6] 0x47df38f6
ppp: FSM: ppp0: State change Req-Sent --> Ack-Sent
ppp: FSM: ppp0: RecvConfigAck(1) state = Ack-Sent
ppp: FSM: ppp0: State change Ack-Sent --> Opened
ppp: LCP : ppp0: LayerUp
ppp

atalink : link name ppp0, Authentication phase: mine = none
Chap Input: CHALLENGE (16 bytes from sms2.dsl.pipex.net)
ppp: Chap Output: RESPONSE ((E-Mail Removed))
Chap Input: SUCCESS (CHAP authentication success, unit 747)
ppp: FSM: Using "ppp0" as a transport
ppp: FSM: ppp0: State change Initial --> Closed
ppp: FSM: ppp0: State change Closed --> Req-Sent
ppp: FSM: ppp0: RecvConfigReq(138) state = Req-Sent
ppp: IPADDR[6]
ppp: FSM: ppp0: State change Req-Sent --> Ack-Sent
ppp: FSM: ppp0: RecvConfigNak(1) state = Ack-Sent
ppp: IPADDR[6]
ppp: <129>[6]
ppp: <131>[6]
PPP: FSM: Sending Lcp Echo Req. restart = 5
ppp: FSM: ppp0: RecvConfigAck(2) state = Ack-Sent
ppp: FSM: ppp0: State change Ack-Sent --> Opened
ppp: IPCP : ppp0: LayerUp. Myaddr = 81.86.224.XX
PPP: IPCP: timer was running so stopping it ...
PPP: IPCP: Starting the LCP Echo Request timer.
ppp: FSM: ppp0: RecvEchoReply(2) state = Opened
PPP: FSM: Lcp Echo Reply recvd from server....
PPP: FSM: Sending Lcp Echo Req. restart = 5
ppp: FSM: ppp0: RecvEchoReply(2) state = Opened
PPP: FSM: Lcp Echo Reply recvd from server....
All is fine.
However with a bust attempt.....
ADSL Link ESTABLISHED !
ppp

atalink : ppp0: Created in Dead state
ppp: FSM: Using "ppp0" as a transport
ppp: FSM: ppp0: State change Initial --> Closed
ppp: FSM: ppp0: State change Closed --> Req-Sent
ppp: FSM: ppp0: RecvConfigReq(16) state = Req-Sent
ppp: LCP : ppp0 : MRU[4] 32725
ppp: LCP : ppp0 : AUTHPROTO[5] 0xc223 (CHAP 0x05)
ppp: MAGICNUM[6] 0x209dd2f2
ppp: FSM: ppp0: State change Req-Sent --> Ack-Sent
ppp: FSM: ppp0: RecvConfigAck(1) state = Ack-Sent
ppp: FSM: ppp0: State change Ack-Sent --> Opened
ppp: LCP : ppp0: LayerUp
ppp

atalink : link name ppp0, Authentication phase: mine = none
ppp: FSM: ppp0: RecvTerminateReq(17) state = Opened
ppp: LCP : ppp0: LayerDown
FsmRecvTermReq: TermReq recieved setting the pppoa flag
ppp: FSM: ppp0: State change Opened --> Stopping
Term Req recvd, closing session 0
ppp: FSM: ppp0: State change Stopping --> Closing
Now restarting the session 0
ppp

atalink : ppp0: Created in Dead state
ppp: FSM: Using "ppp0" as a transport
ppp: FSM: ppp0: State change Initial --> Closed
ppp: FSM: ppp0: State change Closed --> Req-Sent
pppoa Reconnect, Adding default route......
ppp: FSM: ppp0: RecvConfigReq(21) state = Req-Sent
ppp: LCP : ppp0 : AUTHPROTO[5] 0xc223 (CHAP 0x05)
ppp: MAGICNUM[6] 0x524593f6
ppp: FSM: ppp0: State change Req-Sent --> Ack-Sent
ppp: FSM: ppp0: RecvConfigAck(1) state = Ack-Sent
ppp: FSM: ppp0: State change Ack-Sent --> Opened
ppp: LCP : ppp0: LayerUp
ppp

atalink : link name ppp0, Authentication phase: mine = none
Chap Input: CHALLENGE (16 bytes from RASB2NRP6.Birmingham)
ppp: Chap Output: RESPONSE ((E-Mail Removed))
ppp: FSM: ppp0: RecvConfigReq(227) state = Opened
ppp: LCP : ppp0: LayerDown
ppp: LCP : ppp0 : MRU[4] 32725
ppp: LCP : ppp0 : AUTHPROTO[5] 0xc223 (CHAP 0x05)
ppp: MAGICNUM[6] 0x23dd0997
ppp: FSM: ppp0: State change Opened --> Ack-Sent
ppp: FSM: ppp0: RecvConfigAck(2) state = Ack-Sent
ppp: FSM: ppp0: State change Ack-Sent --> Opened
ppp: LCP : ppp0: LayerUp
ppp

atalink : link name ppp0, Authentication phase: mine = none
Chap Input: CHALLENGE (18 bytes from ERX1.GS1)
ppp: Chap Output: RESPONSE ((E-Mail Removed))
Chap Input: SUCCESS
ppp: FSM: Using "ppp0" as a transport
ppp: FSM: ppp0: State change Initial --> Closed
ppp: FSM: ppp0: State change Closed --> Req-Sent
ppp: FSM: ppp0: RecvConfigNak(1) state = Req-Sent
ppp: IPADDR[6]
ppp: <129>[6]
ppp: <131>[6]
ppp: FSM: ppp0: RecvConfigAck(2) state = Req-Sent
ppp: FSM: ppp0: State change Req-Sent --> Ack-Rcvd
ppp: FSM: ppp0: RecvConfigReq(111) state = Ack-Rcvd
ppp: IPADDR[6]
ppp: FSM: ppp0: State change Ack-Rcvd --> Opened
ppp: IPCP : ppp0: LayerUp. Myaddr = 81.178.242.156
PPP: IPCP: Starting the LCP Echo Request timer.
ppp: Chap Output: RESPONSE ((E-Mail Removed))
Chap Input: SUCCESS
ppp: FSM ppp0: Oops, Up at Opened
pppoaTransmitData: PPP negotiation not complete, packet dropped
PPP: FSM: Sending Lcp Echo Req. restart = 5
ppp: FSM: ppp0: RecvEchoReply(1) state = Opened
PPP: FSM: Lcp Echo Reply recvd from server....
pppoaDataReceived: Unexpected IP packet, PPP negotiation not complete
pppoaTransmitData: PPP negotiation not complete, packet dropped
Looks like in the fail condition they are not sending the CHAP challenge.
Trying to resolve this with Pipex.
Dave