not much time to troubleshoot today, here is where I stopped last night.
chained 1,2,3,4 controllers together , 123 controllers work fine play seq. number 4 green light blinks,
run test , only see 1 2 3. connect number 4 stand alone . works fine play seqs. and green light test shows # 4
all are G3 pc16 controllers with 1.06 firmware.
changed cat 5 between 3-4 many diff times.
QUESTION: only difference from last year is new laptop with Windows 10 windows 7 last year.
not sure what to check next, will check rj45 pins again in morning light.