Ok, to eliminate the CONFIG error I've gone back to one flight mode, not GPS related (Attitude / Attitude / AxisLock / Manual) but am leaving Attitude Estmiation Algorithm set to GPS Navigation (INS13) because I want to use the magnetometer on the GPS (explained why below).
I think now the problem is that MAG is black (off) in system health. I've carefully followed the full calibration procedure many times. The vehicle frame is aluminum (conductive but relatively non-magnetic material), but I have the GPS mounted on a non-metallic stalk about 20cm above the metal frame & about 40cm from other electronics & antennas. Most of the high-current wiring (ESCs, some of the power leads) are mounted on the underside of the frame away from electronics. The batteries (3x 6S) are mounted within 20cm of the FC, but 40cm from the GPS. When calibrating the magnetometer I use a plastic table and work gloves to avoid interference, but I am fairly close to the house. Could that be it? GPS was picking up 10-11 satellites at the time of calibration. I tried both Cliff's suggestion to set home position via GPS and setting it manually through the map. FC is connected to GCS via OpLink telemetry.
I did extend the wires from the FC to the GPS by about 40cm, but GPS status is green and appears to be working.
In System --> Settings / AuxMagSettings Type is set to '"GPSV9" and Usage is "AuxOnly". Is this correct?
At this point MAG is black & ATTI and STAB are red (due to MAG I assume).
Thanks for taking a look. Ideas / suggestions always welcome.