I've had the same issue, I believe it is an incompatibility between versions
- Only way I have found is to delete each action and re-enter settings.
- It's not a big deal, as just take a screenshot and then delete and re-enter same settings - just a pain really.
It's not because of dedicated signals, I only use internals for any action moves and I get the same thing.
- Yep, I hear you about 1000 projects etc.......
- Trouble is users do not feedback these bugs (including myself) to Kawasaki, so therefore they may not be aware of these things.
The projects still run as normal, and you can add to the actions, just the existing settings thing is a pain.....
I've been tinkering with the action settings and it seems you can only set a max value of 255.
- I therefore think they are now using internal signals (within KROSET) - earlier versions they had them piggy backed on the Controller signals so you had to use the Controller signals.
- It seems they have freed these up and are using a completely isolated set of signals now.
- I'll drop Kawasaki an email to verify this and see if this intentional or not and let you know.
In version 1.7.2 there is a bug that limits the signals in the 'Action' field to standard output signals only.
- This is why the error appears as the values exceed the limits.
- However existing projects that use internal signals will still 'simulate' as normal, just unable to edit them, temp workaround like I said is to delete and set again using standard output signals.
Later version (yet to be released) this will be fixed to allow internal signals again.
Maybe there is too much 
going on......
