Regarding the geometry error - frames pulled via indi w/ Ekos and other clients (PixInsight included) are definitely different than those captured with TheSkyX on Linux (incl RPi) for at least the FLI drivers. As an example I get overscan margins w/ indi but not with TSX. It's probable that other cameras are similar. I wouldn't be surprised if this is the case.
PixInsight will error if the image geometry (matrix size, possibly pixel depth too) is not exactly the same between the calibrating frame and the frame to be calibrated - they can't line up.
And what's more, the flats and darks do not give me: ** Warning: The FITS format does not define an unambiguous orientation of pixel data. The coordinates read on the image may be wrong.
So it's just the lights that seem to contain the unambiguous orientation data.
My lights are also RAW16 so they are not debayered. But I think that is not the point. PixInsight doesn't seem to be able to unambiguously determine the orientation.
Could it be that there is some information added in the keywords that causes this?