Well after another remote tuning sesion, I am not much further ahead. The CAS seemed to be syncing but was still not providing a consistent signal for the Haltech. We tried a few different settings including batch fire injection and wasted spark. That's where things got interesting... the COPs melted in seconds of loading the tune, even before starting the engine. ☹️ Basically as soon as we rebooted the ECU (as you have to after every ECU software change).
I don't think it was the tune as much as a glitch in the Haltech that caused the COPs to latch power. Only three melted. I believe it was cylinders 2, 4 & 6, but I might be wrong. I should have written that down before pulling them.
I am waiting for the arrival of some new COP's to reset the software and try again. I also moved the Home signal from one reluctor to the other (B pin to C pin) on the OneSix CAS to see if that helps signal fidelity. Tim (from OneSix) apparently recommends that we use Signal Ground from the Haltech versus Home and Trigger ground in the wiring, so that was done as well.
I opened the valve cover and inspected the cam to see if any of the keepers/lash pads had slid off, causing valve issues but alas, they were fine. So no easy "aha!" moment to be found there. I ordered a NOID light test kit as well, so I will confirm the injectors are firing as they are supposed to. I confirmed all the injectors a re working properly with a 9v battery test. Clicking away happily. The Individual spark was confirmed prior to the meltdown.
Hoping to have some good results soon with the new COPs. If not, I think I will have to consider trashing this CAS and rebuilding the engine setup to run a crank trigger. Not what I wanted to do....