I do not understand why you refuse to visualise the spline and just check what is going on… Also, count the spline points, perhaps you create too many. You never answered any of my questions so I honestly can’t help.
edit:
How are you actually creating the points / rotations for the array? Are you reading the transforms of that pre-positioned mesh? If so, this might be reason for the inconsistent behaviour - you’re expecting a specific spline shape but it may not work the way you think.
You must see the shape of the spline, this should answer some questions.