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Hi Steve,
I checked my ImageCalibration settings and the only difference to yours was that I had the Master Dark optimization threshold at the default setting of 3.0. I set it to 0.0 as you had it and still didn't get the error. This is a bit mysterious...
The master flat you sent me has some areas around the borders where the pixel values are zero but it's certainly not an empty flat. Can you open the master flat in PI and see what the Statistics process prints for you?
If you have the original bias, darks and flats I think it would be worth running the lot through BPP. Let me know how it goes.
Cheers,
Rick.
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