May help other iPolar owners.
OK there may be progress - further analysis needed. If I'm on the right track, the manual needs an update! V2.04 page 6 shows the mount rotated in RA during calibration, and states that 2 positions are needed. It also says "The start and end positions can be arbitrary." I'm starting to think this may not be true. On all the previous failed attempts, I started with counterweight bar horizontal, weight west / scope east for "position 1". Then I moved to weight down / home position for "position 2".
The manual v2.04 only shows "position 1 and 2" being needed for calibration, and the software stated calibration successful on all the previous failed attempts.
Last night for a change I started with counterweight bar horizontal, weight east / scope west. Software took that as position 1, asked for position 2. Moved to weight down / home position. Software took that as position 2. THEN asked me for position 3. Never done that before - and NOT in manual. Moved to bar horizontal weight west. Software accepted that as position 3, and quoted me an optical centre that looked vaguely sane - unlike previous attempts.
Polar aligned using latest calibration and started imaging.
At the end of night, PHD2 log analysis shows 0.9 arcmins PA error. And the cross was not EXACTLY over the dot. in the iPolar app.
I want to do some another calibration run, to check the answer is the same, and obviously some more polar aligns and guiding, to make sure this is repeatable. But I may be getting somewhere.
Paul