Finally got to the bottom of this! Jeremy thanks for your help.
It was a bad controller card in the HDPro. Had swapped the Kona card and the CalDigit RAID card and we were running at only 1x. Swapped RAID card, Cables, same result. They shipped me a new controller card for the HDPro and poof! Boot up issue gone and I can now capture ProRes422. So it must look at the lane speed and throw a panic if it's not 4x, but for ProRes only.
Well, Back up and running thought I'd post the conclusion here. And Shane! awe, nevermind..... ;-)
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