I/O Auto Configuration

Working with an M-16iA and R-J3. What would prevent this controller from auto-configuration of the I/O? The appropriate variable is set to TRUE, but with every power cycle, if I delete all the assignments, the configuration lists digital inputs and digital outputs from 1-512 unassigned. Or, if I try to manually configure, it will maintain what I've entered after cycling power but say the configuration is invalid.

As a side note, it takes an abnormally long amount of time for the controller to create the I/O tables at startup... if I try to view the I/O menu too quickly, it says something to the effect of 'menus not created, try again.'

I feel like I've been through a similar situation once before, but cannot recall for the life of me what the issue was. And initial attempts at searching under the new format have been fruitless, so I apologize if this has been addressed here already (as I am sure it has been).

Oddly, the cable on I/O interface JD1B was connected to JRS8 on the operator's interface board instead of JD1A on the CPU. This robot was purchased used, so the previous owner must have had it plugged in there for a reason, but it did not work for model-A I/O. If anyone knows why it would have been connected this way, I'd be interested to know.

I've also been getting SRVO-043 on this robot right after boot. We just got these 2 identical robots, so I've swapped about everything I could possibly swap between the two trying to isolate the problem; amplifiers, redundant ESTOP boards, regenerative resistors, even the actual arms. The fault stays with the controller regardless. Going to send it off after the holidays unless, by chance, someone here has seen this before and has a solution...

Unfortunately, I need to revive this thread. I sent this controller back to our vendor. They found a 'loose connection.' I got it back and let it run idle for several hours, and sure enough, it seemed like the problem had been resolved.

Fast forward a couple months, and I've placed the robot (M-16i) and controller (R-J3iB) into the work cell. There are actually 2 identical robots in this cell, and robot A has no problems. Robot B, however, is once again throwing SRVO-043 right at startup... unless I start with the key switch in T1 or T2 with the pendant turned on. In fact, I can jog the robot around all day long if I boot in teach mode. But as soon as I turn the key back to Auto, I get SRVO-043 DCAL on axes 1 and 2.

I've gone through all of the suggested remedies from the manual. I've swapped just about everything I can swap between these 2 robots to no avail. I've re-seated every connector I can find. This is driving me crazy.

Could this be a software glitch? Can I swap CPUs between these 2 robots? Maybe there is a problem with the backplane? If anyone has any suggestions, I'd love to hear them...