I've come to the conclusion that the auto_linefeed setting has nothing to do with my problems (and that makes sense really)
I can now print most of the time I test, but not always. Though once I can start printing it keeps working for that session
It has to be some kind of initialisation/timing issue between the beeb and retro-printer, but will keep testing until I can consistently make it work and fail on demand, which should hopefully point to what I need to do and why (it's not a case of using the on/off button on the R-P though)
I have all 3 jumpers removed, I wish I knew if the Beeb does need 5v on any of them though
So far it seems issuing *FX5,1 straight after switching on the beeb is enough to prevent the hanging (not sure why as this should be the default)
Have re-enabled the 5v pin I had enabled previously without any problems
So now can print from Sinclair QL, BBC & C64 without needing to change any settings
Next up is the ZX Spectrum 48K, but I think my centronics interface (kempston) is non-functional so will be a while before I get anywhere with this one. May return to the TI-99/4a as I have a different centronics interface available for that now