Thanks for the replies guys.
Sounds like I am the only one with the issue, with that in mind I re-installed OOTP just in case something had changed in the settings.
Downloaded file from server, attempted to download new file (even though I have the latest) same issue, would have expected a 'you already have the latest file' message.
Knocked off AV, same result
Copied all the settings directory files out, downloaded accounts_data file off server, tested download file settings - successful, was able to to export file to server in game as well.
Attempted again to download latest file, becomes unresponsive and fails on cannot download file error after around 20 minutes of hanging.
Grrrr
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