Lack of reproducibility in the DIAPOPS results but not on the agarose gel analysis of the liquid phase PCR products indicates that the PCR is working as expected, but that the problem is in the detection of the solid phase product by hybridization after PCR.
Problems associated with binding of the solid phase primer before PCR would result in a uniform change of the DIAPOPS results. Insufficient washing after the binding procedure with the solid phase primer would be reflected by inhibition of the PCR which would be detected by the agarose gel analysis of the liquid phase PCR product.
The most likely reason for the lack of reproducibility in the DIAPOPS results is in the hybridization detection procedure of the solid phase product after the PCR. The following factors may cause the problem: