Having reverted to KStars 3.3.6 on Windows I can now run the polar alignment tool successfully for the first time. It was crashing the whole application on attempting to solve the error after taking the 3rd image on KStars 3.3.8 on Windows 10, and also on KStars 3.3.7 running on the Raspberry Pi 4.
I have managed to work around my solver issues by installing ansvr on Windows now and pointing the online solver at localhost:8080 where I am running this service. So at least I can now do quick offline solves on the Windows laptop now.

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