I did read many other posts on the same topic, none of which resolved the issue.
I also read other posts which cite the theory behind how this is supposed to work, others that indicate there may be problems with this particular CCD chip's low noise and still others that indicate that hot pixels remaining after calibration is a normal tradeoff. The problem here though is not incomplete hot pixel removal, but zero adu or no hot pixel removal - over or under correction.
I also simply integrated the master bias dark and flats and followed this "simplified" workflow posted by vicent peris
http://pixinsight.com/forum/index.php?topic=2564.msg17291#msg17291 which produced the same dreadful results - zero adu images.
I also tried using the matched flat darks that I captured instead of scaling the master dark so that I could rule out the optimization as an issue and the hot pixels remain - turning optimization on or off had no effect.
I am unable to post the bias/dark images online, but I can say there is nothing wrong with any calibration frames... It is either the calibration process as done by the user or the software behind it. I have successfully calibrated other target images with the same dark/bias using Nebulosity, AIP4WIN and CCDSoft with no hot pixels remaining.
Both the bias and dark frames were acquired with a QSI 583 CCD which uses the KAF8300 chip. Both bias and dark are very high quality - made up of over 200 individual frames each which were measured for temperature fluctuations, cosmic ray hits and other anomalies. All frames were measured to be the correct temp (-20C) and all medians were consistent within a few ADU.
I have programmed and tested software for over 15 years. I don't pretend to understand image processing to that extent, but if the no correlation message was due to improperly subtracting the bias, and I used the same, single bias frame to calibrate a single set of target frames in a single operation, one would think the error condition would apply to the entire set of target images. Yet, in some of the tests I have ran the last couple of days, the message only occurs randomly. In one case, it occurred 5 out of 16 times, implying that either the software is indeed struggling to find a solution or the console messages are incorrect.
Thanks