Thanks for the help so far - things aren't working yet but I have more debug 
information to share.  
- I have now removed the pppd options file completely
- I am still using the same chat script for manual connection and diald - manual works
- I have modified diald.conf to contain the ppp options that I think I need.

Both the chat script and the the diald.conf are attached to the bottom of this message 
as is the error log I get from "tail -f /var/log/messages'.  Unfortunately, diald 
still seems to behave as before.  There do seem to be a lot of messages in the log but 
they don't mean much to me - help!

  Iain Stevenson




My chat script:

ABORT   'BUSY'                  
ABORT   'NO CARRIER'            
ABORT   'NO DIALTONE'           
''      'AT&F'                                          
OK\r\n  'ATD08450885128'        
CONNECT ''

My diald.conf:

mode ppp
connect "/usr/sbin/chat -t15 -V -f /etc/ppp/chat_script"
disconnect "/usr/sbin/chat -t15 -V -f /etc/ppp/chat_disconnect_script"
device /dev/ttyS0
speed 115200
modem
lock
crtscts
local 192.168.1.1
remote  192.168.1.100
dynamic
defaultroute
debug 24
pppd-options idle 180 asyncmap 0 kdebug 24 noipdefault user xxx/yyy
include /usr/lib/diald/standard.filter

Messages logged by 'tail -f /var/log/messages' after starting diald.

Sep 15 21:06:39 Wallace diald[1200]: keepup parsing error. Got token 'tcp.ssl'.
Not a known tcp service port.
Sep 15 21:06:39 Wallace diald[1200]: parse string: 'tcp 120 tcp.dest=tcp.ssl'
Sep 15 21:06:39 Wallace diald[1200]: keepup parsing error. Got token 'tcp.ssl'.
Not a known tcp service port.
Sep 15 21:06:39 Wallace diald[1200]: parse string: 'tcp 120 tcp.source=tcp.ssl'
Sep 15 21:06:39 Wallace modprobe: can't locate module tap0
Sep 15 21:06:39 Wallace modprobe: can't locate module tap1
Sep 15 21:06:39 Wallace modprobe: can't locate module tap2
Sep 15 21:06:39 Wallace modprobe: can't locate module tap3
Sep 15 21:06:39 Wallace modprobe: can't locate module tap4
Sep 15 21:06:39 Wallace modprobe: can't locate module tap5
Sep 15 21:06:39 Wallace modprobe: can't locate module tap6
Sep 15 21:06:39 Wallace modprobe: can't locate module tap7
Sep 15 21:06:39 Wallace modprobe: can't locate module tap8
Sep 15 21:06:39 Wallace modprobe: can't locate module tap9
Sep 15 21:06:39 Wallace modprobe: can't locate module tap10
Sep 15 21:06:39 Wallace modprobe: can't locate module tap11
Sep 15 21:06:39 Wallace modprobe: can't locate module tap12
Sep 15 21:06:39 Wallace modprobe: can't locate module tap13
Sep 15 21:06:39 Wallace modprobe: can't locate module tap14
Sep 15 21:06:39 Wallace modprobe: can't locate module tap15
Sep 15 21:06:39 Wallace diald[1201]: Proxy device established on interface sl0
Sep 15 21:06:39 Wallace diald[1201]: start sl0: SIOCSIFMETRIC: Invalid argument
Sep 15 21:06:39 Wallace diald[1201]: start sl0: SIOCSIFMTU: Invalid argument
Sep 15 21:06:40 Wallace diald[1201]: Diald initial setup completed.
Sep 15 21:06:47 Wallace diald[1201]: Trigger: udp       192.168.1.1/1046   194.1
31.104.225/53
Sep 15 21:06:47 Wallace diald[1201]: Calling site 192.168.1.100
Sep 15 21:06:49 Wallace diald[1201]: connector: AT&F
Sep 15 21:06:49 Wallace diald[1201]: connector: OK
Sep 15 21:06:51 Wallace diald[1201]: connector: ATD08450885128
Sep 15 21:06:51 Wallace diald[1201]: Connected to site 192.168.1.100
Sep 15 21:06:51 Wallace diald[1201]: Running pppd (pid = 1223).
Sep 15 21:06:51 Wallace pppd[1223]: pppd 2.3.7 started by root, uid 0
Sep 15 21:07:51 Wallace diald[1201]: pppd startup timed out. Check your pppd opt
ions. Killing pppd.
Sep 15 21:07:51 Wallace diald[1201]: start sl0: SIOCSIFMETRIC: Invalid argument
Sep 15 21:07:51 Wallace diald[1201]: start sl0: SIOCSIFMTU: Invalid argument
Sep 15 21:07:51 Wallace diald[1201]: start sl0: SIOCADDRT: File exists
Sep 15 21:07:51 Wallace diald[1201]: start sl0: SIOCADDRT: File exists
Sep 15 21:07:51 Wallace pppd[1223]: Terminating on signal 2.
Sep 15 21:07:51 Wallace pppd[1223]: Exit.                                          

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